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Variable Density Insole

by Gyrobot, published

Variable Density Insole by Gyrobot Dec 6, 2014

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6407Views 1805Downloads Found in Biology
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Summary

One of the avenues I am investigating is the problem of foot ulceration, common in diabetes sufferers. This can lead to a serious chain of events leading to over 6000 related amputations a year in the UK. It is estimated that about 80% of these are preventable. Treatment costs to the NHS in the UK are in excess of £650m/annum. It is hoped that a low cost custom insole that is sympathetic to the patients requirements could help dramatically in this scenario.

I see 3D printing taking the initiative and leading the solutions once again.

This is my latest insole creation. A variable density infill print from a foot scan in Filaflex.

Please see more on my blog here (specifically part 3) :
http://www.gyrobot.co.uk/blog/my-adventures-with-3d-printed-insoles-part-1-4
http://www.gyrobot.co.uk/blog/my-adventures-with-3d-printed-insoles-part-2-4
http://www.gyrobot.co.uk/blog/my-adventures-with-3d-printed-insoles-part-3-4
http://www.gyrobot.co.uk/blog/my-adventures-with-3d-printed-insoles-part-4-4

Video : http://youtu.be/ix5e9w-F4HQ

EDIT 10/06/2016 : This work is superseded by my software over at http://www.gensole.com

http://www.gyrobot.co.uk
http://www.facebook.com/gyrobotuk

Instructions

I used Gimp to separate out the regions.

Then Inkscape to make the vector files.

I then exported .dxf files from Inkscape, which can then be imported in to a cad program.

Once the curves have been turned into stls, then its over to Slic3r and using it's modifier mesh option, different infill densities can be applied to different regions.?

Please see more on my blog here (specifically part 3) :
http://www.gyrobot.co.uk/blog/my-adventures-with-3d-printed-insoles-part-1-4
http://www.gyrobot.co.uk/blog/my-adventures-with-3d-printed-insoles-part-2-4
http://www.gyrobot.co.uk/blog/my-adventures-with-3d-printed-insoles-part-3-4
http://www.gyrobot.co.uk/blog/my-adventures-with-3d-printed-insoles-part-4-4

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Hi Gyrobot,
My name is Dario. I am a high school student and I'm working on a similar project for school.
I like to call my project Precision Insole Printing (PIP) because I think it is the future in the medical world for the production of insoles for people with rheumatic feet and diabetes for example.
My idea is as follows, the traditional way of producing the insoles for patients is now milling or making the sole handmade. Both of these ways result in pollution by micro-dust. I think that if we use 3D printing, instead of eliminating the material laying it down, we can solve the pollution problem and have a faster and preciser production method.

I think it is super cool to see someone else working on something similar and equally important!
Hope to hear if you have succeeded and i'm very interested in (and impressed by) your infill techniques.
This because I had a view interviews with some podiatrists, and they told me to support the feet in another way.

Supercool idea!

Dario

Hi Dario,
Thank you for your kind words. I have now further advanced this design and printing technique. Combining variable density infills and form fitting the upper surface to a foot scan reduced peak plantar pressure by 33% on initial trials, ideal for diabetic patients

Please see http://www.gyrobot.co.uk/uploads/1/6/8/8/16887130/3074511_orig.jpg

Cheers,
Steve.

Gyrobot,

I have read through your blog posts but am stump as to how you came out with the "Heat Map" type image to identify where the pressure was when the foot was flat. Is this a further step or did you re-colour the areas to demonstrate a point?

The reason I ask this is that I know for myself I put more pressure on the outside of my feet as I have a Pronated instep but my father favours Prenation and heavier heel pressure. So I was hoping that I could find a way to vary these infill settings based on something like this rather than Guessing.

Thanks for the extremely detailed and useful blog.

Tim

Fantastic idea and work! As TheGreenFilament said, this would make a basis for a great diabetic sandal--just add straps!

is this so that the more weight, the tighter the infill or viceversa? (or something else?)

The higher pressure areas (in red) I have made softer with a looser infill. I want to try and reduce foot ulceration in Diabetes sufferers and I thought this would be the best way round although I may be wrong?

no, your right, just coud'nt see from the picture. Great job! I'm trying to make a flip flop kind of thing like this, except with pla or abs so it could be cheaper. however, flex filament would do a great job to make a cheap insole too, and i think many will love this design. Keep up your good work!

Brillant idea!

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