Custom Orthotic Insole Using DDM
 Alhassane Dienta
 Thomas Koser
 Chiagoziem Uzor
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Table of Contents
 DDM Overview
 SME Competition
 Idea Generation/Insole Background
 Why DDM ?
 Design Process
 Prototype Testing
 Cost Analysis
 Conclusion
 Acknowledgements
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DDM Overview
 DDM (Direct Digital Manufacturing)
- Also know as “3D printing” or “additive
manufacturing ,” “rapid manufacturing”
- Process of making 3 dimensional objects from
digital file
- Large variety of Materials
- DDM as a game changer
“the market is starting to take off, growing
at a clip of up to 35 percent annually”
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– Armed Forces Journal 2011
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The Competition
2012 Design for Direct Digital Manufacturing Competition
Design Challenge
Judging Criteria
- The designed product will be a
device, mechanism, assembly or a
subassembly representing part of another
product. The resultant design should
represent a fully working prototype. Any
internal electronics or mechanics must be
specified within the design. The geometry of
the design must be defined within a threedimensional (3-D), computer-aided design
(CAD) system capable of producing robust
STL files.
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Criteria
Weight of Criteria
Functionality Impact Analysis
20%
Cost/Benefit Analysis
15%
Justification of DDM Material
15%
Justification of DDM Process
15%
Component Integration
15%
Innovative Geometrical Features Via
DDM
10%
Judges Discretion
10%
Total
100 %
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Idea Generation
 Brainstorming
 Customized Orthotic Insole background
- Orthotic insoles are a very popular and effective way of correcting and adjusting to
foot problems like over-pronation and supination which ultimately lead to plantar fasciitis,
heel pain, ankle instability, heel spurs, knee pain, and lower back pain.
- Millions of Customers
- Our design is a custom ¾ length rigid orthotic insole to help restore regular foot bio
mechanics. The ¾ length covers from the heel to the end of the metatarsals
- The rigidity of the orthotic is due to its function: support and alignment.
 Market Research
- Custom Orthotics cost
between $400-$600
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Why DDM ?
 Totally Customized to patients foot
- The orthotic is customized to patients requirements due to the production
procedure
 Cost Effective for producer
- Use of less raw materials and lesser amount of man power saves a
lot of production cost
 Unlimited Complexity
- Easily matches the contours of the feet and shoes
 Eliminate lag time between design and production.
- 24 hour turn around time from doctor visit to collection of fully
customized orthotic insole
 Enable More Flexibility
- Alterations in the design can easily be made directly using the CAD
package
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Design Process
 Two Proposals – Scanning and Clay Imprint
 Scanning
- Using a NextEngine Scanner to scan foot and send data to CAD package for
adjustments
Scan Feet and
Insole
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Minor adjustments
in CAD Package
STL file sent to
Objet30 for printing
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Final Product in approx.
15 hours
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Design Process
 Clay Imprint
A clay imprint was performed by stepping on clay inside a wooden box,
the clay was allowed to dry and using a measurement system, the foot
dimensions were recorded and put into SolidWorks
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Design Process
 SolidWorks Adjustments
- With the model in solidworks, changes were made as required. The
dimensions of the foot were checked for accuracy
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Design Process
 Printing
- The model is to be printed on an objet30 desktop printer.
- Printer chose due to type of material required. The material used is
DurusWhite430 Cure. It is a polyproylene-like material that possesses the
properties required functional orthotic insoles
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Testing
 The main objective of this test experiment is to
demonstrate the difference of pressure distribution
between flat insoles and custom DDM modeling
insoles. Preliminary, a series of tests were done for the
selection of the material.
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Material Tested
Material
Poissons Ratio
Dencity (lb/in^3)
PE High Density
0.400
0.0343932
155190.38
0.4289
PE Medium Density
0.428
0.0331287
64140.39
0.4399
PE Low Density
0.441
0.029382
24946.49
0.452
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Elasttic Modulus (psi) Sepcific Heat ( BTU/lb ° F)
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Preliminary Testing Result
Foot area
Forefoot
Midfoot
Heel
Forefoot
Midfoot
Heel
Forefoot
Midfoot
Heel
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Displacement(in)
4.65E-04
2.80E-04
5.59E-04
4.86E-04
3.39E-04
5.81E-04
1.64E-03
9.13E-04
2.19E-03
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Material
PE High Density
PE Medium Density
PE Low Density
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Preliminary Testing Result
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Testing Result
Name
Type
Min
Max
Stress1
VON: von Mises
Stress
0 psi
Node: 60
22.5958 psi
Node: 18184
combineddone-SimulationXpress_Study-Stress-Stress1
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Comparing of Models
(a)
[3]
(b)
(c)
Figure Comparison of stress distribution of the three models.
Figure a is the current market custom-molded insole
Figure b is the DDM custom insole
Figure c is a simulation of flat surface insole
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Cost Analysis
Table 1: Cost Analysis
Expense
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Cost
Objet30 3D Desktop Printer
$32,000
NextEngine 3D Scanner
$3,000
Maintenance
$5,000
Total Initial Cost
$40,000
Total Material Cost
$6.12/c.i.
$135
Labor -$20/hr for 3
$60
Orthotic Set Cost
$195
Selling price
$425
Profit per Orthotic
$230
Amount needed to cover cost
174
Max yearly output
584
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Conclusion
 The DDM process allows for a quick transition
between design and production
 Foot scanning is a faster, more efficient way of
measuring foot dimensions
 Design alterations can be made easily in the CAD
package
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Acknowledgment
Capstone Advisors
Byungki Kim, Ph.D.
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Stephen Johnston, Ph.D.
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Any Questions?
 DDM Overview
 SME Competition
 Idea Generation/Insole Background
 Why DDM ?
 Design Process
 Preliminary Testing
 Testing Result
 Cost Analysis
 Conclusion
 Acknowledgements
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