Colloquia

Summary

Custom-made insoles play a crucial role in supporting the musculoskeletal system and addressing underlying pathologies. Most custom-made insoles are crafted from foam blocks and shaped through subtractive manufacturing techniques. Although these traditional foam insoles have proven effective in treatment, they come with inherent limitations. Innovative manufacturing techniques, such as additive manufacturing, offer advantageous features like form freedom, internal geometry, and the ability to create less voluminous insole designs. The relatively recent emergence of 3D-printed insole presents opportunities for exploration. The primary objective of this thesis is to develop a method to generate customized 3D insole models based on user-specific input parameters, suitable for 3D printing. By undertaking this research, the aim is to contribute to the progression of 3D-printed insoles and ultimately improve the quality of health services.

This thesis identifies crucial parameters for insoles, forming the basis of a parametric design approach. The project starts by developing a singular 2D model, drawing inspiration from a reference study. The methodology of this initial 2D approach undergoes refinement, progressing to the next stage where it evolves into a 2.5D approach encompassing five cross sections. In a finite element environment, five 2D assemblies comprising a foot, insole, and midsole are established. Each assembly represents a distinct cross-section of the foot, corresponding to each of the five metatarsals. The parametrized approach facilitates the generation of iterative designs, allowing for the creation of a dataset based on iterative simulation results. Using this dataset, an optimal design can be derived based on specific input and objective parameters. This methodology is implemented using a 3D foot model, from which five 2D cross-sections are derived. Through an iterative process for each of the five sections, an optimal shape is determined and subsequently developed into a 3D model. This 3D model is then incorporated into a post-processing framework, which transforms its shape into a suitable insole model for 3D printing.  The finalized and optimized 3D model is ultimately printed, marking the conclusion of the project.