giuliacosco

DigitalAid

Orthotic Insoles

DigitalAid is a Project I worked on as R&D Product Designer for Michelotti Orthopaedc Solutions and Thinking Additive during 2017-2018.

During this project I was living in Lucca, Tuscany. My primary responsibility was to develop a configurator capable of generating personalized orthotic insoles from 3D user foot models (3D meshes). Designed for use by Orthopaedic Technicians, the configurator incorporated advanced geometries and features to support posture correction and improve gait. Additionally, I developed algorithms to enable this functionality and conducted extensive 3D printing tests. These tests assessed printing settings, material properties, and the mechanical performance of the insoles to ensure optimal results.

The design process I followed was the Iterative Design Science Research

Research Focus: Personalized Orthotic Insoles

1. Contextual Research

Conducted an ethnographic study to observe real-life use and needs for orthotic insoles.
Held stakeholder interviews with orthopedists (medical needs) and engineers (design and manufacturing challenges).
Performed secondary research on:
- Biomechanical principles for orthotics.
- Additive manufacturing (AM) in orthopedics.
- FDM technologies and their mechanical performance.
- Materials testing and evaluation for Design for Additive Manufacturing (DfAM), focusing on durability, flexibility, and biocompatibility.

This research combined user insights, medical expertise, and advanced manufacturing techniques to develop innovative solutions for custom orthotic insoles.

Key Findings

Printing Process Issues
- Challenges with printing speed, infill optimization, and surface finishing impacted quality and efficiency.
Material Performances
- Evaluated durability, flexibility, and biocompatibility to ensure comfort, safety, and long-term use.
3D Model Generation Issues
- Difficulties with accuracy, print compatibility, and geometry optimization for functional designs.
Surface Patterns to Control Mechanical Behavior
- Designed patterns to adjust stiffness and flexibility, tailoring insoles for posture correction and gait improvement.

Design Process: Key Aspects

Insole Generation Flow
- Defined steps to transform 3D foot scans into functional, customized insoles.
3D Model Generation Algorithms
- Developed algorithms to automate and optimize insole design based on user data.
3D Model Details
- Integrated surface textures and patterns to enhance flexibility and support.
Building Direction and Printing Position
- Optimized printing orientation for structural integrity and material efficiency.
3D Printing Settings
- Fine-tuned parameters like speed, layer height, and infill for quality and performance.

Design Process: Key Aspects

Insole Generation Flow
- Defined steps to transform 3D foot scans into functional, customized insoles.
3D Model Generation Algorithms
- Developed algorithms to automate and optimize insole design based on user data.
3D Model Details
- Integrated surface textures and patterns to enhance flexibility and support.
Building Direction and Printing Position
- Optimized printing orientation for structural integrity and material efficiency.
3D Printing Settings
- Fine-tuned parameters like speed, layer height, and infill for quality and performance.

Final Evaluations: Key Aspects

Printing Process
- Assessed the overall quality and efficiency of the 3D printing workflow to ensure reliable production.
Printing Settings
- Evaluated print speed, layer height, and infill density to optimize balance between quality, strength, and cost.
Materials
- Tested different materials for durability, flexibility, and biocompatibility to ensure optimal insole performance.
Finishing
- Evaluated post-processing techniques to achieve smooth surfaces and precise features for comfort and functionality.
Mechanical Properties
- Analyzed the insoles' strength, flexibility, and wear resistance to ensure they met biomechanical requirements.
Insoles Fitting
- Assessed the fit of the insoles on users to confirm comfort, support, and effectiveness in correcting posture and gait.

Wrapping Up

What I’ve Learned

Experience in Building 3D Model Configurators - Gained hands-on experience in designing and developing 3D configurators, allowing for the automation of custom orthotic insole creation based on user-specific foot data.

DfAM Knowledge and Printing Tests Experience - Developed a strong understanding of Design for Additive Manufacturing (DfAM) principles, including how to optimize 3D models for printing. Conducted extensive material and printing tests to evaluate the best configurations for performance, durability, and comfort.

Orthopedic Knowledge - Deepened my understanding of orthopedic needs, specifically how custom orthotics can address biomechanical issues such as posture correction, pressure distribution, and gait improvement.

Wrapping Up

Experience in Building 3D Model Configurators - Gained hands-on experience in designing and developing 3D configurators, allowing for the automation of custom orthotic insole creation based on user-specific foot data.

DfAM Knowledge and Printing Tests Experience - Developed a strong understanding of Design for Additive Manufacturing (DfAM) principles, including how to optimize 3D models for printing. Conducted extensive material and printing tests to evaluate the best configurations for performance, durability, and comfort.

Orthopedic Knowledge - Deepened my understanding of orthopedic needs, specifically how custom orthotics can address biomechanical issues such as posture correction, pressure distribution, and gait improvement.