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.

1.
J.
Widjaja
and
W.
Widjaja
, “
3-D reconstruction of foot plantar surface by using incoherent structured illumination
,”
Optik (Stuttg)
., vol.
126
, no.
24
, pp.
5725
5728
, Dec.
2015
.
2.
M. L.
Jain
,
S. Govind
Dhande
, and
N. S.
Vyas
, “
Virtual modelling of an ankle foot orthosis for correction of foot abnormality
,”
Robot. Comput. Integr. Manuf.
, vol.
27
, no.
2
, pp.
257
260
, Apr.
2011
.
3.
M.
Hossain
and
N.
Makwana
, “
‘Not Plantar Fasciitis’: The differential diagnosis and management of heel pain syndrome
,”
Orthop. Trauma
, vol.
25
, no.
3
, pp.
198
206
, Jun.
2011
.
4.
A.
Raspovic
,
L.
Newcombe
,
J.
Lloyd
, and
E.
Dalton
, “
Effect of customised insoles on vertical plantar pressures in sites of previous neuropathic ulceration in the diabetic foot
,”
Foot
, vol.
10
, no.
3
, pp.
133
138
,
2000
.
5.
N.
Steinberg
,
G.
Waddington
,
R.
Adams
,
J.
Karin
,
R.
Begg
, and
O.
Tirosh
, “
Can textured insoles improve ankle proprioception and performance in dancers?
,”
J. Sports Sci.
, vol.
0414
, no. December, pp.
1
8
,
2015
.
6.
K.
Lee
, “
Custom-made Golf Insole Recommender System for Optimizing The Foot Balance During Golf Swing
,”
J. Korea Soc. Comput. Inf.
, vol.
20
, no.
11
, pp.
89
95
,
2015
.
7.
B. M.
Nigg
,
M. A.
Nurse
, and
D. J.
Stefanyshyn
, “
Shoe inserts and orthotics for sport and physical activities
.,”
Med. Sci. Sports Exerc.
, vol.
31
, no.
7
Suppl, pp.
S421
8
,
1999
.
8.
P.
Hinz
,
A.
Henningsen
,
G.
Matthes
,
B.
Jager
,
A.
Ekkernkamp
, and
D.
Rosenbaum
, “
Analysis of pressure distribution below the metatarsals with different insoles in combat boots of the German Army for prevention of march fractures
,”
Gait Posture
, vol.
27
, no.
3
, pp.
535
538
, Apr.
2008
.
9.
G. M.
Ivanic
, “
Orthotics and insoles for the forefoot: The European way
,”
Foot Ankle Clin.
, vol.
8
, no.
4
, pp.
671
682
, Dec.
2003
.
10.
C.
Mavroidis
,
R. G.
Ranky
,
M. L.
Sivak
,
B. L.
Patritti
,
J.
DiPisa
,
A.
Caddle
,
K.
Gilhooly
,
L.
Govoni
,
S.
Sivak
,
M.
Lancia
,
R.
Drillio
, and
P.
Bonato
, “
Patient specific ankle-foot orthoses using rapid prototyping
.,”
J. Neuroeng. Rehabil.
, vol.
8
, no.
1
, p.
1
, Jan.
2011
.
11.
D. P.
Sinn
,
J. E.
Cillo
, and
B. A.
Miles
, “
Stereolithography for craniofacial surgery
,”
J. Craniofac. Surg.
, vol.
17
, no.
5
, p.
869
875
, Sep.
2006
.
12.
J. W. K.
Tong
and
E. Y. K.
Ng
, “
Preliminary investigation on the reduction of plantar loading pressure with different insole materials (SRP - Slow Recovery Poron®, P - Poron®, PPF - Poron®+Plastazote, firm and PPS - Poron®+Plastazote, soft
),”
Foot
, vol.
20
, no.
1
, pp.
1
6
, Mar.
2010
.
13.
Y. A.
Jin
,
J.
Plott
,
R.
Chen
,
J.
Wensman
, and
A.
Shih
, “
Additive manufacturing of custom orthoses and prostheses - A review
,”
Procedia CIRP
, vol.
36
, pp.
199
204
,
2015
.
14.
M.
Yarwindran
;
N.
Azwani Sa’aban
;
M.
Ibrahim
;
P.
Raveverma
, “
Thermoplastic elastomer infill pattern impact on mechanical properties 3d printed customized orthotic insole
,” in
ARPN Journal of Engineering and Applied Sciences - to be published
.
15.
M. H.
Burhan
,
M.
Yarwindran
, and
M.
Ibrahim
, “
Design and fabrication of an orthotic insole by using Kinect ® Xbox gaming sensor scanner and 3d printer
,”
ARPN J. Eng. Appl. Sci. - to be Publ. - Unpubl.
16.
R.
Shah
, R.,
Pani
,
D.
, &
Acharya
, “
Get Your Feet Scanned. (Podiatech Sidas Medical
),” 2013. [Online]. Available: http://www.podiapro.in/get-your-feet-scanned/. [Accessed: 29-Apr-2016].
This content is only available via PDF.
You do not currently have access to this content.