Parametric modeling and performance analysis of a personalized insole based on 3D scanning and selective laser sintering

Current design methods of individualized insoles are confronted with much-repeated work and are over-reliance on experiences. To tackle these problems, parametric modeling and selective laser sintering (SLS) were integrated for automatically generating personalized insoles in this study. 3D scanning was first used to achieve an individual's foot model and then an innovative parametric modeling program with an automatic line drawing module based on Grasshopper was developed. Additionally, both personalized insoles and flat insoles were manufactured via SLS technology and their performances were evaluated with finite element analysis and a Footscan system. The results show that the proposed parametric method of individualized insoles largely reduces the workload in comparison to traditional design, and can conveniently regulate the insole design for agreeable foot comfort. And the developed customized insoles with complex array structure can be successfully manufactured with SLS technology. Additionally, the personalized insole can reduce the peak contact pressure by 30% compared with the flat insole, and increase the strength and the durability of the insole, which is mainly attributed to the foot-fitting surface and the adopted array structure. The advantages and potential applications of the proposed parametric modeling method coupled with SLS technology were also discussed.