3D Printed Personalized Orthotic Inserts Using Photogrammetry and FDM Technology

Orthotic shoe inserts are the most prominent fixtures used in shoes/sneakers of the sportspersons to accurate biomechanical foot issues. One size fits all doesn’t work in these cases, as foot shape, curvature, and arch height from person to person differs. As of now, personalized inserts are very expensive due to the conventional manufacturing approach. With improved manufacturing technology, additive manufacturing the future is looking bright and promising. Manufacturing of inserts requires the need for soft or flexible material, which can be exploited conveniently using fused deposit modelling (FDM) technology. In this chapter, inserts have been modeled using unique android phone cameras and free computer software’s based on photogrammetry technology, which has the capability to converts a series of 2D images into 3D models with STL file format. Then, the scanned model is smoothened in Mesh mixer software. Subsequently, upon making the changes in the model, the final product is printed and tested for its appropriateness for use. While the product developed is a low cost due to the simple, yet customized manufacturing method, the comfort delivered by the inserts are highly satisfactory.