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Custom Orthotic Insole Using DDM

Custom Orthotic Insole Using DDM. Alhassane Dienta Thomas Koser Chiagoziem Uzor. Q/A. Table of Contents. DDM Overview SME Competition Idea Generation/Insole Background Why DDM ? Design Process Prototype Testing Cost Analysis Conclusion Acknowledgements. Q/A. DDM Overview.

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Custom Orthotic Insole Using DDM

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  1. Custom Orthotic Insole Using DDM • Alhassane Dienta • Thomas Koser • Chiagoziem Uzor Q/A

  2. Table of Contents • DDM Overview • SME Competition • Idea Generation/Insole Background • Why DDM ? • Design Process • Prototype Testing • Cost Analysis • Conclusion • Acknowledgements Q/A

  3. 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” – Armed Forces Journal 2011 Q/A

  4. The Competition 2012 Design for Direct Digital Manufacturing Competition Design Challenge - 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 three-dimensional (3-D), computer-aided design (CAD) system capable of producing robust STL files. Judging Criteria Q/A

  5. 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 Q/A

  6. 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 Q/A

  7. Design Process • Two Proposals – Scanning and Clay Imprint • Scanning - Using a NextEngine Scanner to scan foot and send data to CAD package for adjustments Minor adjustments in CAD Package Final Product in approx. 15 hours STL file sent to Objet30 for printing Scan Feet and Insole Q/A

  8. 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 Q/A

  9. Design Process • SolidWorks Adjustments - With the model in solidworks, changes were made as required. The dimensions of the foot were checked for accuracy Q/A

  10. 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 Q/A

  11. 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. Q/A

  12. Material Tested Q/A

  13. Preliminary Testing Result Q/A

  14. Preliminary Testing Result Q/A

  15. Testing Result Q/A

  16. Comparing of Models Q/A

  17. Cost Analysis Q/A

  18. 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 Q/A

  19. Acknowledgment Capstone Advisors Byungki Kim, Ph.D. Stephen Johnston, Ph.D. Q/A

  20. 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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