The feasibility study on fabrication customized orthotic insole using fused deposition modelling (FDM) Available to Purchase

There are many important roles of the orthotic insoles, such as for the convenience purpose of diabetic patient’s foot problem, and also to enhance athlete’s performance in sports. Therefore, highly customised insoles were in demand, where it has to be fabricated by moulding plaster of Paris on the person’s leg to customise the insole. The main purpose of the paper is to study the ability to implement additive manufacturing technology in the fabrication process of customised orthotics insole. The recent invention of flexible material (Filaflex) in Fused Deposition Modelling is the most significant reason that makes this fabrication process possible. By implementing a new approach to the 3D scanning of the foot, we produced the computer-aided drafting (CAD) drawing which was able to modify to desired shape and dimension. After the editing has been completed, the file was converted to Stereolithography format file (STL) as to enable it to be printed using Makerware or any other related software by sending command (G-code) to Flashforge 3D printer. The printed insole was tested its fit, form and function (also known as 3F). In the end, printed insole performs the function test which measures the plantar pressure of the foot compared with bare foot. The results show that the insole distributes pressure well throughout the foot surface, in which it reduced the peak pressure to half from 218KPa to 109KPa. Hence, it is concluded that the method proposed in this paper can produce a functional insole so that it can be the alternative way to make customised orthotic insoles.