Research on functional insole optimization design based on plantar pressure and material properties using FEM

Purpose This study aims to develop a functional insole that balances cushioning, comfort and support. Using finite element simulation and material testing, it evaluates how different insole structures and materials affect plantar pressure distribution and foot stability to provide optimized design solutions for daily and sports footwear. Design/methodology/approach First, a foot–insole–ground finite element model was built to simulate pressure and displacement under standing conditions. Then, material tests (air permeability, water-vapor transmission, abrasion resistance) were conducted on six commercial insoles. Based on the results, a new insole with a honeycomb structure, arch support and a heel cup was designed and validated. Findings The optimized insole effectively reduced peak pressure in the heel and forefoot, while providing better arch support. It showed good air permeability and water-vapor transmission, and maintained low mass loss under abrasion. It also improved comfort and stability. Originality/value This study combines finite element simulation with material performance testing to optimize insole design in a quantitative way. The honeycomb structure with targeted arch and heel support offers a new solution for balancing cushioning, breathability and stability, providing a practical reference for functional footwear development.