Combining dynamic foot scanning and additive manufacturing for the production of insoles: a case study

The development of an insole that is representative of the foot’s dynamic nature is crucial for good fit as well as comfort and performance. Additive manufacturing (AM) has the potential to allow the production of such insoles because of its tool-less capabilities and the ability to directly manufacture from CAD models at no extra cost. Research therefore has been undertaken to explore a process of foot capture by using a dynamic scanner for the design and manufacture of insoles using AM. The feet of four individuals were dynamically and statically scanned and from these data, four insole designs were developed for each person. The designs were: footprint, dynamic, average and static. The results indicated that the personalisation process is complex, mainly due to the need to identify and select the point cloud(s) from a large number of frames and manipulate them accordingly, presenting challenges in the design phase. The data from this study have demonstrated that combining dynamic scanning and AM technology is feasible for developing personalised insoles. While traditional footwear/insole is based on static data, this study can be considered as a starting point for the development of personalised insoles by using dynamic scanning and AM.