Design and development of fused deposition modeling (FDM) 3D-Printed Orthotic Insole by using gyroid structure

The orthotic insole is a device that is placed between the bottom of the foot and the sole of the shoe. It bears the body weight and directly influences the biomechanics of the foot and the body. These insoles are used to minimize the stress by reducing plantar pressure between support points hence minimizing the pressure. Such customized insoles have usually been produced by either handmade or subtractive methods. Fused deposition modeling (FDM) has opened innovative ways for the manufacture of orthotic insoles. In recent studies, no specific computer-aided design (CAD) tools are available to design and manufacture the insole, which is the primary focus. This work aims to evaluate established CAD techniques for designing and fabricating insoles utilizing different manufacturing processes. The evaluation is based on a prior analysis of the possibilities for functionalizing insole materials and structures. In this study, multiple software tools are utilized for designing custom insoles, considering pressure points and a three-dimensional (3D) foot scan of an individual. The research highlights how the implementation of software enables a significant level of customization by integrating pressure mapping data into the insole design process. A novel CAD approach for designing an orthotic insole has been provided in this work. Soft poly-lactic acid (PLA) is used to fabricate an insole using FDM technology. The gyroid and solid samples were evaluated following ASTM standards. When compared to the solid construction, the gyroid structure has a high specific energy absorption capability, which is used to create the orthotic insole. The results of the experiment suggest that the selection of the structure for customized insole design is significantly affected by the infill density parameter.