Automated rapid design method for personalized gradient pressure-relieving insoles

To improve the fit and design efficiency of pressure-relieving insoles, this study proposes an automated rapid design method for personalized gradient pressure-relieving insoles based on foot morphology and plantar pressure. The proposed method involves three key steps: acquiring and integrating foot morphology and plantar pressure data, designing structural units and mapping relationships, and generating insole contours. The insole design relies on the Point Cloud Library. The effectiveness of the insole was validated by customizing the insoles for each subject and comparing the plantar pressure distribution during static standing and dynamic walking under three conditions: without insoles, with flat insoles, and with gradient pressure-relief insoles. Results showed that the gradient pressure-relieving insoles significantly reduced peak plantar pressure and increased the contact area compared to flat insoles. The entire design-to-production process was completed within 1 week. The findings indicate that personalized gradient pressure-relieving insoles offer effective functionality, adaptability, and a short production cycle, with potential for clinical application and healthcare advancement.