CN110959955A - A manufacturing method of additive manufacturing orthopedic insole based on unstable walking - Google Patents
A manufacturing method of additive manufacturing orthopedic insole based on unstable walking Download PDFInfo
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- CN110959955A CN110959955A CN201911214908.1A CN201911214908A CN110959955A CN 110959955 A CN110959955 A CN 110959955A CN 201911214908 A CN201911214908 A CN 201911214908A CN 110959955 A CN110959955 A CN 110959955A
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- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
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Abstract
The invention provides a manufacturing method of an orthopedic insole based on unstable walking by additive manufacturing, which comprises the following steps of (1) data acquisition: measuring the static pressure data and dynamic pressure data of the sole of the foot of the tester by using a foot pressure plate; (2) and (3) data analysis: analyzing the static pressure data and dynamic pressure data of the sole; (3) modeling the orthopedic insole: on the basis of the sole static pressure data, utilizing Easy CAD software to perform insole modeling, importing sole dynamic pressure data, and calculating the thickness of the insole; (4) optimizing the orthopedic insole: utilizing magics software to generate an orthopedic insole model with a cellular porous structure; (5) manufacturing an orthopedic insole by adding materials: printing the three-dimensional model of the orthopedic insole to obtain an insole primary product; (6) and (3) post-treatment: removing support, polishing and grinding the printed insole; (7) and (3) finished product: and adhering the fabric to the shoe pad after the post-treatment, and polishing along the edge. The application also provides an orthopedic insole prepared by the preparation method.
Description
Technical Field
The invention relates to the technical field of orthopedic insoles, in particular to a manufacturing method of an orthopedic insole based on unstable walking.
Background
The manufacturing method of the orthopedic insoles on the market mainly comprises the following steps: the shoe pad is made up by using traditional plaster model shoe pad and adopting plaster bandage to make negative form, plaster positive form and plastic plate material to make high-temp. forming or manually beating metal material. The method has long manufacturing time and high technical requirements on manufacturers. In addition, there is also a method for preparing orthopedic insoles by obtaining information of patients through a computer, and the common method is as follows: the insole is manufactured according to foot pressure, the size of the planar insole is obtained by acquiring static pressure data of the foot and generating a pressure map, the height of the insole is obtained by carrying out finite element data analysis design on the foot pressure data according to a pressure dispersion principle and utilizing a formula, so that a model is obtained in a summary manner, and the insole is printed out in a 3D manner. However, only the static pressure of a patient is considered, the height of the insole is calculated according to a static pressure finite element formula, and the exercise biomechanics of a tester are not considered, so that the height of the insole prepared by the method is not accurate, the insole does not accord with the exercise biomechanics of the patient, gait line and posture are abnormal due to long-time walking, and the hip, the knee and other parts are seriously affected.
In view of the above, there is a need to provide a method for manufacturing an orthopedic insole based on unstable walking by using additive materials to solve the existing problems.
Disclosure of Invention
One of the purposes of the invention is to provide a manufacturing method of an orthopedic insole based on unstable walking, which has the advantages of short manufacturing period, less raw material waste, good comfort and capability of maximally conforming to personal sports biomechanics, and avoids the inaccuracy of manufacturing a personalized orthopedic insole by only utilizing static plantar pressure.
The invention also aims to provide the orthopedic insole prepared by the manufacturing method.
In order to achieve the purpose, the invention provides a manufacturing method of an orthopedic insole based on unstable walking by additive manufacturing, which comprises the following steps:
(1) data acquisition: measuring foot pressure data of a tester in two natural states of standing and walking by using a foot pressure plate to obtain plantar static pressure data and plantar dynamic pressure data, wherein the plantar dynamic pressure data comprise dynamic pressure distribution, a gait line and a gait cycle;
(2) and (3) data analysis: judging whether the pressure distribution of the left foot and the right foot is symmetrical, whether the pressure of the front and the rear soles is too concentrated, whether the maximum stress point moves forwards or not and whether the inner and the outer splayfoot exist or not according to the static pressure data of the soles; judging whether a gait line is normal or not and the gait cycle swings according to the dynamic pressure data of the foot soles, wherein the dynamic pressure distribution is used for judging whether the pressure distribution of the left foot and the right foot is symmetrical or not, whether the pressure of the front palm and the rear palm is too concentrated or not, whether the maximum stress point moves forwards or not and whether an inside-outside splayfoot exists or not; the gait line is used for judging whether flat feet, arched feet, metatarsalgia, heel pain of horseshoe and unstable gravity center exist, the gait cycle is used for judging whether walking is abnormal and is matched with the gait line to judge whether the gravity center exists unstable;
(3) modeling the orthopedic insole: on the basis of the sole static pressure data, utilizing a correction module database in Easy CAD software to perform insole modeling, importing sole dynamic pressure data, and calculating insole thickness;
(4) optimizing the orthopedic insole: utilizing magics software to generate an orthopedic insole model with a cellular porous structure;
(5) manufacturing an orthopedic insole by adding materials: printing the three-dimensional model of the orthopedic insole by using an additive manufacturing technology to obtain an insole primary product;
(6) and (3) post-treatment: cutting off redundant fabric at the edge of the primary insole product, removing the support, polishing and grinding;
(7) and (3) finished product: and adhering the fabric to the shoe pad after the post-treatment, and polishing along the edge.
Preferably, the step (1) further comprises acquiring a digital footprint by using a 2D scanner, so as to grasp the shape of the foot of the tester.
Preferably, in the step (4), the cellular porous structure is hexagonal.
Preferably, the distance between opposite sides of the hexagon is 2.5 mm.
Preferably, the distribution density of the honeycomb-shaped porous structure is 8/cm2。
Preferably, the axial heights of a plurality of said honeycomb cellular structures are different.
Preferably, the fabric is a mixed fabric of EVA, cloth and PV.
Correspondingly, the application also provides the orthopedic insole prepared by the manufacturing method of the orthopedic insole based on the unstable walking additive manufacturing.
Compared with the prior art, the manufacturing method of the orthopedic insole based on the unstable walking additive manufacturing utilizes the static pressure data and the dynamic pressure data of the sole to design the personalized orthopedic insole, particularly analyzes the three data of dynamic pressure distribution, gait lines and gait cycles to obtain accurate data, and meanwhile, the orthopedic insole adopting the honeycomb porous structure design is different from the orthopedic insole which is designed on the market by utilizing the thickness to perform the orthopedic operation, thereby improving the orthopedic effect, prolonging the service life and saving raw materials. Therefore, the method for manufacturing the insole of the orthopedic insole has the advantages of short manufacturing period, less raw material waste, good comfort and capability of maximally conforming to personal sports biomechanics, and avoids the inaccuracy of manufacturing the personalized orthopedic insole by only utilizing static plantar pressure.
Drawings
Fig. 1 is a test chart of static pressure data of sole of a patient before correction.
Fig. 2 is a test chart of the static pressure data of the sole of a foot of a tester after correction.
FIG. 3 is a test chart of dynamic pressure distribution data before correction.
FIG. 4 is a test chart of the corrected dynamic pressure distribution data.
Fig. 5 is a test chart of gait cycle data before correction.
Fig. 6 is a test chart of the measured data of the 2D scanner.
Detailed Description
The present invention is further explained with reference to specific embodiments, which are described in detail and specific, but not to be construed as limiting the scope of the invention, and all technical solutions obtained by equivalents or equivalent changes should be included in the scope of the claims of the present invention.
The invention relates to a manufacturing method of an orthopedic insole based on unstable walking by additive manufacturing, which comprises the following steps:
(1) data acquisition: measuring the foot pressure number of a tester in two natural states of standing and walking by using a foot pressure plate to obtain sole static pressure data and sole dynamic pressure data, wherein the sole dynamic pressure data comprises dynamic pressure distribution, a gait line and a gait cycle;
(2) and (3) data analysis: analyzing the plantar static pressure data and the plantar dynamic pressure data, and judging whether the left foot pressure and the right foot pressure are symmetrical, whether the front and back foot pressures are too concentrated, whether the maximum stress point moves forwards, and whether an inside and outside splayfoot exists; whether flat feet, arched feet, metatarsalgia, hoof heel pain and unstable gravity center exist, judging whether walking is abnormal or not in the gait cycle, and judging whether unstable gravity center exists or not by matching with the gait line;
(3) modeling the orthopedic insole: on the basis of the sole static pressure data, utilizing a correction module database in Easy CAD software to perform insole modeling, importing sole dynamic pressure data, and calculating insole thickness;
(4) optimizing the orthopedic insole: utilizing magics software to generate an orthopedic insole model with a cellular porous structure;
(5) manufacturing an orthopedic insole by adding materials: printing the three-dimensional model of the orthopedic insole by using an additive manufacturing technology to obtain an insole primary product;
(6) and (3) post-treatment: cutting off redundant fabric at the edge of the primary insole product, and polishing and grinding;
(7) and (3) finished product: and adhering the fabric to the shoe pad after the post-treatment, and polishing along the edge.
The following describes a manufacturing method of the additive manufacturing orthopedic insole based on unstable walking according to the application in combination with specific test data.
(1) The foot pressure plate is used for measuring foot pressure data of a tester in two natural states of standing and walking, the tester visually observes the front and naturally breathes and relaxes to obtain sole static pressure data and sole dynamic pressure data, the collected sole static pressure data and sole dynamic pressure data are fed back to the computer controller by the foot pressure plate, and a FEREESTEP software measuring system is used for generating dynamic pressure distribution, gait cycle and gait line. And measuring the toe angle and the metatarsal angle by adopting a 2D scanner, wherein the toe angle is used for judging whether the hallux valgus exists or not, and the metatarsal angle is used for judging whether the metatarsal valgus exists or not. Referring to the test chart of the measured data of the 2D scanner in fig. 6, in the present embodiment, the metatarsal angle is 21, which is a normal condition.
(2) And (3) judging whether the pressure distribution of the left foot and the right foot is symmetrical, whether the pressure of the front and the rear soles is too concentrated, whether the maximum stress point moves forwards or not and whether the pressure exists in the inner splayfoot or the outer splayfoot according to the static pressure data of the soles obtained in the step (1). The dynamic pressure distribution is used for judging whether the pressure distribution of the left foot and the right foot is symmetrical or not, whether the pressure of the front and the rear soles is too concentrated or not, whether the maximum stress point moves forwards or not and whether an inside and outside splayfoot exists or not; the gait line is used for judging whether flat feet, arched feet, metatarsalgia, heel pain of horseshoe and unstable gravity center exist, the gait cycle is used for judging whether walking is abnormal or not, and the gait line is matched for judging whether unstable gravity center exists or not.
In this embodiment, referring to fig. 1, the static pressure data test chart of the sole of the patient before correction is obtained in step (1). As can be seen from fig. 1, the ratio of the front foot to the rear foot is 62%, the ratio of the rear foot to the front foot is 38%, and the difference is large (normally 45% -50%), so it is determined that the front and rear sole pressures are too concentrated on the front foot, and the maximum stress point is forward movement, which results in unstable walking.
Referring to fig. 3, a test chart of the dynamic pressure distribution data before correction is obtained in step (1). The line trend in fig. 3 is the gait line. Fig. 5 is a test chart of gait cycle data before correction. As can be seen from FIGS. 3 and 5, the test subjects had excessive forefoot pressure, unstable heels, and abnormal gait lines. The real-time gait line swings sharply, basically the pressure center of each frame swings, the fourth five metatarsal bones are not stressed, and the first two metatarsal bones are stressed in a biased way towards the front two and three four metatarsal bones, so that the first two metatarsal bones are stressed excessively. The normal gait line is the line approaching its foot shape from the heel to the arch, through the four and five metatarsals, the two and three metatarsals, and finally out the big toe. The gait line shown in fig. 3 is not close to the foot shape and is not smooth, that is, the gait line is zigzag, which indicates that the acting point of the tester is unsteady during walking, and the unsteady swing can cause uneven distribution of dynamic stress, the acting point is unsteady at the hindfoot and directly reaches the two and three metatarsal bones without passing through the arch of the foot, so that the stress of the forefoot is too large, the walking is unstable, and the result is consistent with the test result of the static pressure data of the sole. According to the data, in the preparation of the orthopedic insole, the instability of the ankle joint and the talus of the cup stabilized is deepened, the metatarsal pad is added at the first two metatarsals to enhance the stability, and the heel 1 degree of the front palm and the back heel is lifted at the same time.
(3) And (3) based on the sole static pressure data, performing insole modeling on the half sole, the heel, the arch and the proprioception in a correction module database in Easy CAD in a targeted manner, importing sole dynamic pressure data, and automatically calculating the thickness of the insole. In order to uniformly disperse the pressure of the foot, the height of the insole is reasonably increased at a place with higher pressure and is reasonably reduced at a place with lower pressure according to dynamic pressure distribution, so that the effect of uniformly dispersing the pressure is achieved. In the process of three-dimensional modeling design, smooth processing is carried out on the uneven part in the model, and local burr error points in the insole model are deleted.
(4) And (3) generating an insole model with a honeycomb porous structure with height difference and dispersed pressure by utilizing magics software, wherein the axial heights of a plurality of honeycomb porous structures are different. This cellular porous structure distributes in the inside and the surface of shoe-pad primary product, and the orientation is vertical direction, and when cellular porous structure received the load of perpendicular to face, its bending rigidity and with the material, with the solid plate difference of thickness nearly nothing, even higher, but its weight is light 70 ~ 90%, and non-deformable is difficult for fracture and fracture moreover to have advantages such as shock attenuation, give sound insulation, thermal-insulated and extremely strong weatherability. The aperture size of the cellular porous structure and other related parameters can be selected according to the requirement,and are not limited herein. In this example, the honeycomb porous structure is hexagonal, and experimental studies have found that when the distance between opposite sides of the honeycomb porous structure is 2.5 mm, the distribution density is 8 pieces/cm2When the size is increased by 0.5 mm, the distribution density is reduced by 1/cm2And in time, the anti-seismic and anti-shake effect is better, the stability is better, and the service life is prolonged. In this example, the distance between the opposite sides of the honeycomb-shaped porous structure was 2.5 mm, and the distribution density was 8 pieces/cm2But not limited thereto. The shape righting insole adopting the cellular porous structure design is different from shape righting by utilizing the thickness on the market, the shape righting effect is improved, and the service life can be prolonged.
(5) And printing the three-dimensional model of the orthopedic insole by using an additive manufacturing technology to obtain an insole primary product. And inputting the format file into a 3D printer, and printing the insole base body by the 3D printer. The material is TPU (thermoplastic polyurethane elastomer rubber) wires.
(6) And cutting off redundant fabric on the insole base body along the edge of the insole base body to obtain an insole primary product, and polishing one circle of the edge of the insole primary product. Specifically, in this embodiment, the cutting machine cuts off the excess fabric on the insole substrate, and the polishing machine polishes the edge of the original insole product for one circle to improve the quality and accuracy of the insole, but not limited thereto.
(7) Coating glue on the upper surface of the primary insole, and sticking the fabric on the glue. According to actual needs, before the fabric is attached to the glue, the steps of attaching a sponge layer to the glue on the upper surface of the primary insole and coating the glue on the sponge layer are further included to further increase the comfort, but the steps are not limited to this. For example, the sponge layer is a memory sponge layer, so that the recovery reliability is improved. The fabric is EV, PV, bamboo charcoal fiber fabric, breathable cotton fabric or imitation leather velvet fabric, but is not limited to EV, PV and bamboo charcoal fiber fabric.
After the orthopedic insole is prepared, a subject can try the orthopedic insole for 3-8 hours every day, and data acquisition is carried out after one and a half of a month, and the results are shown in fig. 2 and 4, wherein fig. 2 is a test chart of the static pressure data of the sole of the corrected tester, and fig. 4 is a test chart of the dynamic pressure distribution data after correction. As can be seen in fig. 2, the nude foot after orthodontics approaches the theoretical value significantly more. Fig. 4 shows that the gait line in the dynamic state also has no significant tortuosity, is more gradual than a few months ago, and is similar to the foot-shaped approach. After a period of correction for more than a month, the ankle instability is obviously cured.
Compared with the prior art, the manufacturing method of the orthopedic insole based on the unstable walking additive manufacturing utilizes the static pressure data and the dynamic pressure data of the sole to design the personalized orthopedic insole, particularly analyzes the three data of dynamic pressure distribution, gait lines and gait cycles to obtain accurate data, and meanwhile, the orthopedic insole adopting the honeycomb porous structure design is different from the orthopedic insole which is designed on the market by utilizing the thickness to perform the orthopedic operation, thereby improving the orthopedic effect, prolonging the service life and saving raw materials. Therefore, the method for manufacturing the insole of the orthopedic insole has the advantages of short manufacturing period, less raw material waste, good comfort and capability of maximally conforming to personal sports biomechanics, and avoids the inaccuracy of manufacturing the personalized orthopedic insole by only utilizing static plantar pressure.
It should be noted that the above-mentioned embodiments illustrate rather than limit the scope of the invention, and that those skilled in the art will be able to modify the invention in its various equivalent forms after reading the present invention and to fall within the scope of the invention as defined in the appended claims.
Claims (8)
1. A manufacturing method of an orthopedic insole based on unstable walking by additive manufacturing is characterized by comprising the following steps:
(1) data acquisition: measuring foot pressure data of a tester in two natural states of standing and walking by using a foot pressure plate to obtain plantar static pressure data and plantar dynamic pressure data, wherein the plantar dynamic pressure data comprise dynamic pressure distribution, a gait line and a gait cycle;
(2) and (3) data analysis: judging whether the pressure distribution of the left foot and the right foot is symmetrical, whether the pressure of the front and the rear soles is too concentrated, whether the maximum stress point moves forwards or not and whether the inner and the outer splayfoot exist or not according to the sole static pressure data; judging whether the gait line is normal or not and the gait cycle swings according to the dynamic pressure data of the sole, wherein the dynamic pressure distribution is used for judging whether the pressure distribution of the left foot and the right foot is symmetrical or not, whether the front and back palm pressures are too concentrated or not, whether the maximum stress point moves forwards or not and whether an inside and outside splayfoot exists or not; the gait line is used for judging whether flat feet, arched feet, metatarsalgia, heel pain of horseshoe and unstable gravity center exist or not, the gait cycle is used for judging whether walking is abnormal or not, and the gait line is matched to judge whether unstable gravity center exists or not;
(3) modeling the orthopedic insole: on the basis of the sole static pressure data, utilizing a correction module database in Easy CAD software to perform insole modeling, importing the sole dynamic pressure data, and calculating insole thickness;
(4) optimizing the orthopedic insole: utilizing magics software to generate an orthopedic insole model with a cellular porous structure;
(5) manufacturing an orthopedic insole by adding materials: printing the three-dimensional model of the orthopedic insole by using an additive manufacturing technology to obtain an insole primary product;
(6) and (3) post-treatment: cutting off redundant fabric at the edge of the primary insole product, and polishing and grinding;
(7) and (3) finished product: and adhering the fabric to the shoe pad after the post-treatment, and polishing along the edge.
2. The method for manufacturing the orthopedic insole based on walking instability according to the claim 1, wherein the step (1) further comprises the step of acquiring digital footprints by using a 2D scanner for mastering the foot shapes of testers.
3. The method for manufacturing an orthopedic insole based on unstable walking by adding materials according to claim 1, wherein in step (4), the cellular porous structure is hexagonal.
4. The method of making an additive manufacturing orthopedic insole based on ambulatory instability according to claim 3, wherein the distance between opposite sides of the hexagon is 2.5 millimeters.
5. The method of claim 3, wherein the cellular structure has a distribution density of 8 cells/cm2。
6. The method of making an additive manufacturing orthopedic insole based on ambulatory instability according to claim 3, wherein the axial heights of the plurality of cellular structures are different.
7. The method of making an additive manufacturing orthopedic insole based on ambulatory instability according to claim 1, wherein the fabric is a hybrid of EVA, cloth, and PV.
8. An orthopedic insole made by the method of making an orthopedic insole based on additive manufacturing of walking instability of any of claims 1-7.
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| CN118216744A (en) * | 2024-03-29 | 2024-06-21 | 晋江市海润医疗科技有限公司 | Design method and system for automatic learning pressure sensing dynamic balance insole |
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