Investigation on the Development of Custom Foot Insole Using Soft Polylactic Acid by Fused Deposition Modelling Technique

Researchers in the medical industry are looking forward for innovative products and methodologies to fabricate health care products such as implants, prosthetics, implants and foot care product. The function of foot improves by using foot orthotics to treat foot abnormalities. The footwear industry is working to produce orthotics with advanced materials accurately at a faster rate. This study aims to develop a custom foot insole by fused deposition modelling method. Polylactic acid polymer is used to fabricate the foot insole. Foot anatomy is scanned using a 2D laser scanner and is converted into a 3D model and is used to print the foot insole. Tests were carried to evaluate the plantar pressure in the foot. The pressure with the insole at the forefoot and hind foot decreases during the static state. The pressure at the hallux, metatarsal I, metatarsal II-V, lateral arc and heel decreases during the dynamic state, while the pressure at the lateral toes and medial mid foot increases while using the foot sole. These foot orthotics improve gait comfort and improve foot-loading characteristics. This method can be efficiently used to fabricate customized foot insoles when compared to conventional fabrication techniques.