giuliacosco

The SportIn3D is a project I worked on 2017 which combined advanced technologies and user-centered design. Developed as part of a collaborative effort, the project focused on creating personalized orthotic insoles for cycling using biometric data and Fused Deposition Modelling (FDM) 3D printing technology.

The design process I followed was the Iterative Design Science Research

Purpose

The goal of the project was to design custom-fit insoles that enhance cycling performance, improve comfort, and ensure precise biomechanical alignment. The insoles were tailored to:

Optimize power transfer and energy efficiency during pedaling.
Support proper lower-limb alignment and correct foot posture.
Reduce localized pressure peaks and biomechanical inconsistencies.
Enhance overall comfort for both static and dynamic cycling conditions.

This approach aimed to provide cyclists with high-performance, customizable insoles designed to meet their individual needs.

In this project, I was actively involved in various critical stages, including:

Biometric 3D Scanning and Data Refinement: Capturing precise foot morphology and processing the data to create accurate inputs for insole customization.
Insole Generation Workflow: Designing a seamless digital pipeline for generating custom insoles.
3D Model Development: Creating algorithms for insole geometry and refining intricate design details.
3D Printing Optimization: Defining the optimal build direction and positioning for efficient and precise manufacturing.
Troubleshooting: Addressing technical challenges throughout the development process.

Printing Tests

Conducting experiments to optimize the printing process and settings.
Selecting appropriate materials to balance durability, flexibility, and comfort.
Performing finishing techniques to improve the surface quality.
Evaluating mechanical properties and conducting fitting tests to ensure user satisfaction.

Design Highlights

The insoles incorporated several innovative features:

Morphology: Fully customized based on individual biometric scans.
Material: High-performance materials, including polymer composites, were used to reduce pressure points and improve overall comfort.
Structure: A contoured design provided stabilization and alignment of the foot.
Functionality: Tailored features ensured optimal power transfer and reduced fatigue during cycling.

Outcome

The SportIn3D project was an excellent opportunity to integrate advanced technologies, biomechanics, and additive manufacturing into a user-centric solution. By focusing on customization, comfort, and performance, the project delivered scientifically validated, high-quality insoles that addressed the specific needs of cyclists.

This project allowed me to develop and refine key skills in 3D scanning, computational design, and 3D printing, showcasing my ability to blend technical expertise with innovative problem-solving in product development.