University of Twente Student Theses


Design and fabrication of an adjustable insole for sports shoes using additive manufacturing

Schilder, Wies (2022) Design and fabrication of an adjustable insole for sports shoes using additive manufacturing.

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Abstract:Podo Lab Twente (PLT) is a company that specializes in the development and production of orthopedic and podiatric facilities. One of the most recent developments within the company is the development of an insole produced by selective laser sintering (SLS) of polyamide 12 (PA12), which is designed for sports shoes especially. Before the insole can be introduced in the market, it should be adjustable post-production. In this study, it was aimed to include two adjustable elements in PLT's PA12 insoles: a metatarsal pad (MP) to relieve the pressures in the forefoot and a hindfoot correction to control supination and pronation during loading response (LR). SLS and vat photopolymerization techniques were used to test the function of the designs. Static analysis of the final design was done by compression tests. The dynamic function was analysed by in-shoe pressure distribution measurements and three dimensional (3D) motion capture with eleven subjects. All materials showed sufficient compression strength to endure plantar pressures during static and dynamic conditions. The MP showed a mean peak pressure (PP) decrease of 2.0 ± 9.2% in the forefoot. This small decrease was probably caused by testing with the MP in fixed position, rather than personalised locations based on the subject's individual anatomy. The hindfoot correction with the torsion axis along the mean STJ axis showed a significant (a = 0.05) mean decrease of 2.13 ± 1.39% ankle pronation and 0.48 ± 0.78% knee abduction during LR. No significant difference was found for tibial rotation. PLT's PA12 insole was redesigned to enable post-production adjustments of an MP and a hindfoot correction. Compression tests showed that the insole provided sufficient strength to bear loads during use. Further research has to be done into the dynamic function of the MP design, possibly leading to a redesign. The hindfoot correction showed the expected dynamic function.
Item Type:Essay (Master)
PLT, Haaksbergen, Netherlands
Faculty:ET: Engineering Technology
Programme:Industrial Design Engineering MSc (66955)
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