Development of personalized cast shoes using 3D printing technology

Abstract The need for personalized protective footwear for patients undergoing cast surgery has led to this research exploring efficient 3D printing methods for custom-made products. Focusing on these patients, this study developed and evaluated a prototype for a custom-made protective cast shoe, demonstrating the practical applicability of 3D printing in this field. The study developed a cast shoe sole using a multi-material printing method with TPU (ThermoPlastic Polyurethane) and ABS (acrylonitrile butadiene styrene). Each prototype's design was tailored based on individual body data, incorporating features like a 3D printed toe cover and a lock to enhance user convenience. The external design of each prototype cast shoe was customized to the participant's cast shape and design preferences. Participants reported that the prototype provided stability and improved cast protection. It was also positively evaluated for usability aspects like weight reduction, mobility, and comfort. Regarding aesthetic satisfaction, the custom-made design received high ratings. In response to the feedback, the final prototype incorporated various improvements to enhance comfort and aesthetics. The prototype cast shoe also considered elements like ventilation, weight reduction, and shortened production time, achieved by including specific patterns in its upper part. This research proposes a 3D printing-based efficient production method for custom-made products, highlighting their practical applicability from a user perspective. This study is significant for bridging the gap between academic research and practical application in the field of 3D printing.