Custom Orthotic Insole Using DDM

Alhassane DientaThomas Koser

Chiagoziem Uzor

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Table of ContentsDDM Overview

SME CompetitionIdea Generation/Insole Background

Why DDM ?Design Process

Prototype TestingCost AnalysisConclusion

Acknowledgements

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DDM OverviewDDM (Direct Digital Manufacturing)

-  Also know as “3D printing” or “additive manufacturing ,” “rapid manufacturing”

- Process of making 3 dimensional objects from digital file

- Large variety of Materials- DDM as a game changer “the market is starting to take off, growing

at a clip of up to 35 percent annually” – Armed Forces Journal 2011

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The Competition

- The designed product will be a device, mechanism, assembly or a subassembly representing part of another product. The resultant design should represent a fully working prototype. Any internal electronics or mechanics must be specified within the design. The geometry of the design must be defined within a three-dimensional (3-D), computer-aided design (CAD) system capable of producing robust STL files.

4

Criteria Weight of Criteria

Functionality Impact Analysis 20%

Cost/Benefit Analysis 15%

Justification of DDM Material 15%

Justification of DDM Process 15%

Component Integration 15%

Innovative Geometrical Features Via DDM

10%

Judges Discretion 10%

Total 100 %

Judging Criteria

2012 Design for Direct Digital Manufacturing Competition

Design Challenge

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Idea GenerationBrainstormingCustomized Orthotic Insole background

- Orthotic insoles are a very popular and effective way of correcting and adjusting to foot problems like over-pronation and supination which ultimately lead to plantar fasciitis, heel pain, ankle instability, heel spurs, knee pain, and lower back pain.

- Millions of Customers - Our design is a custom ¾ length rigid orthotic insole to help restore

regular foot bio mechanics. The ¾ length covers from the heel to the end of the metatarsals

- The rigidity of the orthotic is due to its function: support and alignment.

Market Research - Custom Orthotics cost

between $400-$600504/22/23 Q/A

Why DDM ?Totally Customized to patients foot

- The orthotic is customized to patients requirements due to the production procedure

Cost Effective for producer - Use of less raw materials and lesser amount of man

power saves a lot of production costUnlimited Complexity

- Easily matches the contours of the feet and shoes

Eliminate lag time between design and production.- 24 hour turn around time from doctor visit to collection of

fully customized orthotic insoleEnable More Flexibility

- Alterations in the design can easily be made directly using the CAD package

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Design ProcessTwo Proposals – Scanning and Clay ImprintScanning

- Using a NextEngine Scanner to scan foot and send data to CAD package for adjustments

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Scan Feet and Insole

Minor adjustments in CAD Package

STL file sent to Objet30 for printing

Final Product in approx. 15 hours

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Design ProcessClay Imprint A clay imprint was performed by stepping on clay inside a

wooden box, the clay was allowed to dry and using a measurement system, the foot dimensions were recorded and put into SolidWorks

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Design ProcessSolidWorks Adjustments - With the model in solidworks, changes were made as

required. The dimensions of the foot were checked for accuracy

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Design ProcessPrinting - The model is to be printed on an objet30 desktop printer.

- Printer chose due to type of material required. The material used is DurusWhite430 Cure. It is a polyproylene-like material that possesses the properties required functional orthotic insoles

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TestingThe main objective of this test experiment is

to demonstrate the difference of pressure distribution between flat insoles and custom DDM modeling insoles. Preliminary, a series of tests were done for the selection of the material.

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Material Tested

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Material Poissons Ratio Dencity (lb/in^3) Elasttic Modulus (psi) Sepcific Heat ( BTU/lb ° F)

0.0343932

0.0331287

0.029382

PE High Density

PE Medium Density

PE Low Density

0.400

0.428

0.441

155190.38

64140.39

24946.49

0.4289

0.4399

0.452

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Preliminary Testing Result

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Foot area Displacement(in) MaterialForefoot 4.65E-04Midfoot 2.80E-04Heel 5.59E-04

Forefoot 4.86E-04Midfoot 3.39E-04Heel 5.81E-04

Forefoot 1.64E-03Midfoot 9.13E-04Heel 2.19E-03

PE High Density

PE Medium Density

PE Low Density

Preliminary Testing Result

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Testing Result

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Name Type Min Max Stress1 VON: von Mises

Stress 0 psi Node: 60

22.5958 psi Node: 18184

combineddone-SimulationXpress_Study-Stress-Stress1

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Comparing of Models

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(a) [3] (b) (c)

Figure Comparison of stress distribution of the three models.

Figure a is the current market custom-molded insole

Figure b is the DDM custom insole

Figure c is a simulation of flat surface insole

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Cost AnalysisTable 1: Cost Analysis

Expense Cost

Objet30 3D Desktop Printer $32,000

NextEngine 3D Scanner $3,000

Maintenance $5,000

Total Initial Cost $40,000

Total Material Cost $6.12/c.i.

$135

Labor -$20/hr for 3 $60

Orthotic Set Cost $195

Selling price $425

Profit per Orthotic $230

Amount needed to cover cost 174

Max yearly output 584

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ConclusionThe DDM process allows for a quick

transition between design and productionFoot scanning is a faster, more efficient way

of measuring foot dimensionsDesign alterations can be made easily in the

CAD package

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Acknowledgment

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Capstone Advisors

Stephen Johnston, Ph.D.Byungki Kim, Ph.D.

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Any Questions?DDM Overview

SME CompetitionIdea Generation/Insole Background

Why DDM ?Design Process

Preliminary TestingTesting ResultCost AnalysisConclusion

Acknowledgements2004/22/23