Optimizing laser 3D printing parameters for customized rubber latex health shoe insoles

Abstract This research explores the use of additive manufacturing, specifically laser 3D printing, to create customized health shoe insoles from natural rubber latex, following ISO/ASTM 52900:2021 standards. By blending natural rubber latex with additives and dispensing the mixture through a syringe nozzle, the process allows for precise extrusion control, while a laser beam cures the latex in real time. Key process parameters—including laser power, beam angle, source distance, nozzle diameter, extrusion rate, and printing speed—were systematically optimized to ensure high precision and efficiency. Additionally, aesthetic properties, such as color and raster angle, were considered to enhance the product’s visual appeal. Mechanical testing, compliant with ISO 37:2024, validated the durability and performance of the printed rubber specimens. Optimal settings of 10 W for laser power, a 45-degree beam angle, 50 mm source distance, 0.85 mm nozzle diameter, 60 mm/s printing speed, and 0.03 mm 3 /s extrusion rate were determined, while adding 1% v/v blue pigment further improved the material’s ultimate strength. The curing process, maintained between 80 °C and 90 °C to avoid degradation, enabled the production of a US size 7.5 insole in under 24 h. This innovative approach significantly reduces production time and cost, offering a scalable and efficient solution for the manufacturing of customized rubber products through additive manufacturing.