Abstract
This study aimed to explore the potential of applying additive manufacturing technology and lattice structure technology in the design and fabrication of orthotic insoles, proposed a digitalised orthotic insole design process that integrates 3D foot scanning, parametric modelling, and 3D printing. The present study also compared this process with traditional orthotic insole production in terms of workflow, operation, and user comfort. The present study adopted research through design (RTD) methodology and a case study approach, conducted in two stages: ‘Insole Design and Development’ and ‘Wear Testing and Verification.’ The design and development process includes 3D foot scanning, data repair, model construction, lattice structure generation, and 3D printing. Rhinoceros 3D and Grasshopper were used for parameter setting, and various plugins and lattice structures were compared to identify the most suitable combination for orthotic insole applications. Subsequently, in collaboration with medical institutions, case-specific designs and practical testing were conducted with three patients exhibiting different foot conditions. Specifically, walking tests and in-depth interviews were performed. The results show that parametric lattice insoles outperformed traditional medical- grade insoles in particular for patients with high arches and flat feet by providing more precise pressure distribution and reduced discomfort. Furthermore, the overall system operation process was intuitive and efficient, allowing for rapid response to diverse foot shapes and symptom-specific design needs. However, the user interface presents a certain entry barrier for beginners, and it is recommended that future development include interface optimisation and automated assistance to enhance practicality.
Keywords
Personalised medicine; Orthotic insoles; Additive manufacturing; Lattice structure; Parametric system
DOI
https://doi.org/10.21606/iasdr.2025.283
Citation
Zhu, S., Lee, L.,and Lin, M.(2025) Exploring the Application of Additive Manufacturing Technology and Lattice Structures in Orthotic Insole Design, in Chang, C.-Y., and Hsu, Y. (eds.), IASDR 2025: Design Next, 02-05 December, Taiwan. https://doi.org/10.21606/iasdr.2025.283
Creative Commons License
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License
Conference Track
Track 3 - Design, Art & Technology
Exploring the Application of Additive Manufacturing Technology and Lattice Structures in Orthotic Insole Design
This study aimed to explore the potential of applying additive manufacturing technology and lattice structure technology in the design and fabrication of orthotic insoles, proposed a digitalised orthotic insole design process that integrates 3D foot scanning, parametric modelling, and 3D printing. The present study also compared this process with traditional orthotic insole production in terms of workflow, operation, and user comfort. The present study adopted research through design (RTD) methodology and a case study approach, conducted in two stages: ‘Insole Design and Development’ and ‘Wear Testing and Verification.’ The design and development process includes 3D foot scanning, data repair, model construction, lattice structure generation, and 3D printing. Rhinoceros 3D and Grasshopper were used for parameter setting, and various plugins and lattice structures were compared to identify the most suitable combination for orthotic insole applications. Subsequently, in collaboration with medical institutions, case-specific designs and practical testing were conducted with three patients exhibiting different foot conditions. Specifically, walking tests and in-depth interviews were performed. The results show that parametric lattice insoles outperformed traditional medical- grade insoles in particular for patients with high arches and flat feet by providing more precise pressure distribution and reduced discomfort. Furthermore, the overall system operation process was intuitive and efficient, allowing for rapid response to diverse foot shapes and symptom-specific design needs. However, the user interface presents a certain entry barrier for beginners, and it is recommended that future development include interface optimisation and automated assistance to enhance practicality.