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Foot orthotic manufacture by additive technology

Discussion in 'Biomechanics, Sports and Foot orthoses' started by NewsBot, Oct 23, 2012.

  1. NewsBot

    NewsBot The Admin that posts the news.


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    An evaluation of personalised insoles developed using additive manufacturing.
    Salles AS, Gyi DE.
    J Sports Sci. 2012 Oct 22.
  2. Is this the first study to be published in which 3D printed orthoses have been employed?
  3. Admin2

    Admin2 Administrator Staff Member

  4. Here's an interesting survey on 3d printing and additive manufacture:


    It seems the open source, low-cost printers are leading the way- good!

    I'm going to see if I can find any open source .stl files of foot orthoses online. If I can't, I'm going to suggest an open source project which won't rely upon grants and European funding, it will simply be done from people's own good will and the desire to help their fellow humans. What I am proposing is that podiatry arena (or another site- maybe I'll contact the Feet First Worldwide charity) holds a depository for prefabricated foot orthoses .stl files which people can access free of charge and print on their open source 3d printers such as RepRap.

    Anyone interested? What say you Phil Wells?
  5. Phil Wells

    Phil Wells Active Member

    Sounds a great idea but IP may be an issue.
    I will however be happy to donate a file when the site is ready.

    Anyone else?

  6. As ever, you're a star. IP won't be a problem if the people contributing the designs are the designers; just like you sir. In essence, a starting point would be one design in small medium and large sizes. But, a "quadrastep" type system might be good?

    Let me think it through a bit more, contact some people and see where this go's. Thanks for your commitment Phil.

    Like the man said, anyone else?
  7. RobinP

    RobinP Well-Known Member

    What would be the production speed for the "average" orthotic ? I can see some really great applications for this in my NHS clinic being off the mainland and the turnaround times involved in getting somthing manufactured "instantly".

    I would love to get involved in prefab CAD design but would probably only be able to do it with assistance - something that the IOM government are actually very good for. I might investigate grants available.

    Thanks for this Simon - given me some ideas
  8. From the paper (thanks Athol),

    "The control condition consisted of the same
    trainers, but fitted with insoles that were manufactured
    from scans of the trainers’ original insoles.
    Thus, the control condition had an identical shape as
    the original insole, but was manufactured using LS
    to have the same thickness (2 mm), stiffness and
    material as the personalised insole."

    No. It didn't have the same stiffness as the personalised insole, at least not across it's entire interface with the foot. This is because it had a different geometry to the personalised insole and as we know, the geometry of the device will influence it's load/ deformation characteristics. Just because two devices are made of the same material, it doesn't mean that they will have the same mechanical properties in-vivo.
  9. I was thinking about a name for the site: The Foot Orthoses Design Depository and Educational Resource (FODDER)

    Food, esp. dried hay or feed, for cattle and other livestock.
    forage - feed - provender

    Any others?

    Robin, I fully expect that in the future the NHS will have a similar depository of virtual orthoses which members of staff can download and print. I'd like to see something not restricted to NHS staff and to be open access.

    Looking at some of the "foot orthoses" being employed in certain study's, I should think it might be helpful for researchers to access designs to use within their studies too.
  10. Phil Wells

    Phil Wells Active Member

    Just out of interest is anyone using the low price 3D printing systems such as RepRap and Makerbot.
    I know of commercial company who tried RepRap but couldn't get the quality of the insole right.

    Re the library of models, it may be possible in the future to get low cost stl modelling software that would allow for arch shaping etc - a semi modular approach- to be done to a standard model, a bit like the original CAD software from the early 90's.

    The IP may be an issue if employers (the owners of the currently very expensive software) don't allow people like me to contribute- lets hope for that lottery win and then the world is our oyster!
  11. javier

    javier Senior Member

    First time I read this thread I thought it was a great idea, but you need to capture a 3D model (cast or foot) to fit the right stl file foot orthotic design with the patients foot.

    After some months researching 3D scanners through Internet, I found this Open Source Project: OPEN NI

    I bought an Asus Xtion Pro 3D sensor and I have tried some good 3D modeling app to get an ultra low cost 3D scanner.

    Here is an example using Skanect and Mesh Lab (Open Source Mesh Edit software) to scan my foot sole

    Also, here is a 3D model from a foam box: https://sketchfab.com/show/zjpFzSXK7RnP6cZvgFU0ByBs6CM

    You scan whatever you want and edit it using Meshlab (OpenSource) and NetFabb Studio Basic (Freeware). Also you can fix a 3D model and save it as a stl file. You can visit this tutorial: How to use MeshLab & Netfabb for fixing your model

    Once, you have your stl file you can print it or share it (or sell it) through websites such as Sculpteo or through other platforms if The Foot Orthoses Design Depository and Educational Resource (FODDER) becomes a reality.

    I think there is a potential here for us. 3D scanning is become more affordable for everybody.

    Attached Files:

    Last edited by a moderator: Sep 22, 2016
  12. NewsBot

    NewsBot The Admin that posts the news.

  13. NewsBot

    NewsBot The Admin that posts the news.

    In-Shoe Innovation: 3D-Printed Foot Orthoses
    Breanne Therese Przestrzelski
    PhD Thesis Clemson University, 2017

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