Affordable 3D printing methodology for the fabrication of orthotic insoles aimed at reducing plantar pressure for diabetic patients

Purpose This study aims to address the pressing need for innovative, accessible and cost-effective healthcare solutions for diabetic foot complications by exploring additive manufacturing, specifically fused deposition modelling (FDM), to create patient-specific orthotic insoles. Design/methodology/approach The research aims to streamline design and production processes, reducing lead times and costs associated with traditional orthotic manufacturing methods. The study involves a detailed examination of FDM technology to produce custom orthotic insoles, focusing on mechanical evaluations of various candidate materials based on their viscoelastic properties. Different infill lattice patterns, such as Honeycomb and Gyroid, are assessed to determine their effectiveness in mitigating plantar pressures. Findings The research outlines a comprehensive workflow for the FDM printing process, highlighting the significance of tailored infill percentages to achieve the desired stiffness levels in the insoles. Filaflex 60A is identified as a suitable material for FDM printing of orthotic insoles due to its favourable viscoelastic properties, comparable to established orthotic materials. Among the tested infill lattice patterns, Gyroid structures demonstrate superior resilience under compression, making them more effective in reducing plantar pressures. Despite challenges such as soft filament handling and printing speed limitations, FDM printing is shown to be a viable alternative to traditional manual techniques, offering benefits in automation and cost-effectiveness. Originality/value This research presents a novel approach to orthotic insole production using FDM technology, significantly contributing to diabetic foot care. By providing a comprehensive workflow and emphasizing the importance of material selection and infill design, the study paves the way for further advancements in patient-specific healthcare solutions through innovative and affordable manufacturing techniques.