Scientists develop custom 3D printed insoles for diabetics

The importance of foot comfort cannot be ignored. In this regard, people with diabetes need to pay more attention. Improper wearing of shoes can make ordinary people feel uncomfortable, but it is dangerous for people with diabetes. Atrophy of the nerve endings caused by diabetes can attenuate or eliminate pain, which in turn can lead to severe foot injuries or wounds. Customized insoles have become an important means of preventing such problems. But until recently, such insoles were still very expensive and not readily available - only through specialized orthopedic footwear companies. Fortunately, recent results indicate that 3D printing is helping to popularize customized insoles.

A German project called LAUF (the acronym for "Diamond-assisted manufacturing of custom-made footwear" in German) shows that 3D printing may be the key to digitally manufacturing insoles. According to Tiangong, LAUF was founded by the Federal Ministry of Education and Research, and its members are composed of industry experts and a group of researchers from the Fraunhofer Institute. The project is demonstrating the advantages of digital foot mapping and 3D printed insoles for diabetics.

Dr. Tobias Ziegler, a scientist at the Raunhofer Institute, explained: “Digital foot mapping is already a common practice. As part of LAUF, we have now fully digitized the insole production process. Using newly developed software The orthopaedic footwear company can design a pair of insoles for a single patient, which can then be printed on a 3D printer."

Researchers say that 3D printing allows them to make customized insoles at a much lower cost, while making them more accessible. In addition to cost advantages, the all-digital process also makes the orthopedic insole's mechanical properties more significant and stronger, which makes them easier to get health insurance companies. They emphasize that having a fully digital insole allows medical insurance companies to collect scientific data on insoles and their efficacy.

The next step in the research is to develop more innovative materials for 3D printed insoles. Covestro and Lehmann & Voss & Co, which used 3D printed insoles with flexible TPU materials a few years ago, are now working with researchers at the Raunhofer Institute to develop new TPU materials for customized insoles.

At the same time, researchers have been designing TUP insoles for 3D structures and geometries for foot construction. Dr. Ziegler explains: “Where does the insole need to be softer or harder? By changing the type of structure, we can accurately determine the hardness of the insole... In order to determine where optimization is needed, we will also simulate the entire production process.”

The insole itself is being printed by the Fraunhofer Institute's industrial partners RPM and Sintermask, both using selective laser sintering (SLS). After the print is complete, the insole prototype will be sent back to the Institute for extensive testing. If the tests prove that they are completely feasible, the software developed by LAUF will be available within two years.