Effects of varying material properties on the load deformation characteristics of heel cushions

Investigating the Effect of Design Parameters on the Mechanical Performance of Contact Wave Springs Designed for Additive Manufacturing

Additive manufacturing (AM) enables design freedom to fabricate functionally graded wave springs designed by varying design parameters, which are not possible in traditional manufacturing. AM also enables optimization of the wave spring design for specific load-bearing requirements. Existing wave springs are manufactured by metal with constant dimensions (width and thickness of the strip, diameter) using customized traditional machines in which design variations are almost impossible. This study aims to investigate the effect of wave height, the overlap between the two consecutive coils, and the number of waves per coil on the mechanical properties, for example, load-bearing capacity, stiffness, and energy absorption of contact wave springs. Two designs, that is, rectangular and variable thickness wave springs, were chosen and the design of experiment was devised using Minitab software, resulting in 24 samples. HP MultiJet Fusion (MJF) printer was used to manufacture the samples for performing uniaxial compression tests up to 10 cycles and 90% of the compressible distance to study the variation in mechanical properties due to changes in parameters. Experimental and simulation results showed that variable thickness wave springs have better load bearing, stiffness, and energy absorption compared with the rectangular counterparts. In addition to that, the number of waves per coil and the overlap are directly proportional to the load-bearing capacity as well as stiffness of the wave springs, while the constant wave height is responsible for more uniformly distributed stresses throughout the coils. Load-bearing capacity was increased by 62%, stiffness by 37%, and energy absorption by 20% once the number of waves per coil is increased from 5 to 6 in rectangular wave springs. Overall, the parametric variations significantly affect the performance of wave springs; thus, designers can choose the optimized values of investigated parameters to design customized wave springs for specific applications as per load/stiffness requirements.

Energy Absorption and Stiffness of Thin and Thick-Walled Closed-Cell 3D-Printed Structures Fabricated from a Hyperelastic Soft Polymer

This study analyses the energy absorption and stiffness behaviour of 3D-printed supportless, closed-cell lattice structures. The unit cell design is bioinspired by the sea urchin morphology having organism-level biomimicry. This gives rise to an open-cell lattice structure that can be used to produce two different closed-cell structures by closing the openings with thin or thick walls, respectively. In the design phase, the focus is placed on obtaining the same relative density with all structures. The present study demonstrates that closure of the open-cell lattice structure enhances the mechanical properties without affecting the functional requirements. Thermoplastic polyurethane (TPU) is used to produce the structures via additive manufacturing (AM) using fused filament fabrication (FFF). Uniaxial compression tests are performed to understand the mechanical and functional properties of the structures. Numerical models are developed adopting an advanced material model aimed at studying the hysteretic behaviour of the hyperelastic polymer. The study strengthens design principles for closed-cell lattice structures, highlighting the fact that a thin membrane is the best morphology to enhance structural properties. The results of this study can be generalised and easily applied to applications where functional requirements are of key importance, such as in the production of lightweight midsole shoes.

Effect of Fillets on Mechanical Properties of Lattice Structures Fabricated Using Multi-Jet Fusion Technology

Cellular structures with tailored topologies can be fabricated using additive manufacturing (AM) processes to obtain the desired global and local mechanical properties, such as stiffness and energy absorption. Lattice structures usually fail from the sharp edges owing to the high stress concentration and residual stress. Therefore, it is crucial to analyze the failure mechanism of lattice structures to improve the mechanical properties. In this study, several lattice topologies with fillets were designed, and the effects of the fillets on the stiffness, energy absorption, energy return, and energy loss of an open-cell lattice structure were investigated at a constant relative density. A recently developed high-speed AM multi-jet fusion technology was employed to fabricate lattice samples with two different unit cell sizes. Nonlinear simulations using ANSYS software were performed to investigate the mechanical properties of the samples. Experimental compression and loading–unloading tests were conducted to validate the simulation results. The results showed that the stiffness and energy absorption of the lattice structures can be improved significantly by the addition of fillets and/or vertical struts, which also influence other properties such as the failure mechanism and compliance. By adding the fillets, the failure location can be shifted from the sharp edges or joints to other regions of the lattice structure, as observed by comparing the failure mechanisms of type B and C structures with that of the type A structure (without fillets). The results of this study suggest that AM software designers should consider filleted corners when developing algorithms for generating various types of lattice structures automatically. Additionally, it was found that the accumulation of unsintered powder in the sharp corners of lattice geometries can also be minimized by the addition of fillets to convert the sharp corners to curved edges.

Study of the Distortion of the Indirect Angular Measurements of the Calcaneus Due to Perspective: In Vitro Testing

The study of the foot is relevant in kinematic analyses of gait. Images captured through a lens can be subjected to various aberrations or distortions that affect the measurements. An in vitro study was performed with a rearfoot simulator to compare the apparent degrees (photographed) with the real ones (placed in the simulator) in the plane of the rearfoot's orientation, according to variations in the capture angle in other planes of space (the sagittal plane and transverse plane-the latter determined by the foot progression angle). The following regression formula was calculated to correct the distortion of the image: real frontal plane = 0.045 + (1.014 × apparent frontal plane) - (0.018 × sagittal plane × foot progression angle). Considering the results of this study, and already knowing its angle in the transverse and sagittal planes, it is possible to determine the angle of a simulated calcaneus with respect to the ground in the frontal plane, in spite of distortions caused by perspective and the lack of perpendicularity, by applying the above regression formula. The results show that the angular measurements of a body segment made on frames can produce erroneous data due to the variation in the perspective from which the image is taken. This distortion must be considered when determining the real values of the measurements.

Analysis and Assessment through Mechanical Static Compression Tests of Damping Capacity in a Series of Orthosis Plantar Materials Used as Supports

High plantar pressure is the cause of multiple types of foot injuries and one of the main reasons for patient visits in podiatry and traumatology. Therefore, there is a need to acquire specific tools to address such injuries. The aim of this study was to determine the absorption capacity of selected materials applied as plantar supports and their response to pressure. The study had a cross-sectional design. A total of 21 materials were chosen and different material families were assessed, including ethylene-vinyl acetate, polyurethane foams, and polyethylene foams. Static compression tests were performed to analyze each material. The system is ideally suited for lower-force applications, small components, biomedical applications, and lower-strength materials. Damping was determined using mathematical calculations performed on the study data. It was found that materials with a low Shore A, or soft materials, exhibited worse absorption capacity than harder materials. Ethyl-vinyl acetates had good absorption capacity, polyurethane foams had a poor absorption capacity, and soft materials provided better adaption to impact. The results suggested that damping is not determined by the hardness of the material, and materials within the same family exhibit different damping capabilities.

Supportless Lattice Structures for Energy Absorption Fabricated by Fused Deposition Modeling

Additively manufactured cellular structures represent a promising engineering design concept for making customized products where user-specific mechanical properties are required. One of the major challenges in the additive manufacturing (AM) process is removal of unwanted support structures from the lattice. The support structure consumes extra material, printing time, and energy for manufacturing. Postprinting, it needs extensive postprocessing work to remove it from the lattice structure chemically or mechanically. In the case of flexible materials such as thermoplastic polyurethane (TPU), removing the support structure from the lattice is very difficult with the material extrusion process. In this article, a new type of a shell-shaped lattice structure inspired by sea urchin (SU) morphology is designed. This lattice can be additively manufactured by material extrusion processes such as fused deposition modeling (FDM) without requiring any support structures. The mechanical properties of the proposed structure, such as stiffness and energy absorption during loading and unloading, have been evaluated as they are important for cushioning. The compressive results indicate that the stiffness property is almost twice as high compared with the benchmarked, bending-dominated, body-centered cubic (BCC) lattice structure of the same relative density and ethylene vinyl acetate (EVA) foam. Energy absorption is almost equal to the BCC lattice and 20% better than EVA foam. Last, a predictive model on stiffness behavior and energy return was developed to facilitate a systematic way to select optimal densities of the SU lattice structure for energy-absorbing applications. Visual inspection has also revealed that there is no sagging or failure of the lattice, which reduced the manufacturing time and postprocessing time, saving a significant amount of material without compromising on quality. Supportless lattice printing was also validated by printing the specimen with a different FDM printer and TPU filament. A possible application for supportless lattice structures can be for AM of customized shoe midsoles at low cost, ski boots, tires, automotive crush boxes, or any other energy-absorbing structures.

The influence of shoe aging on children running biomechanics

Athletic children are prone to overuse injuries, especially at the heel and knee. Since footwear is an extrinsic factor of lower limb injury risk, the aim of this study was to assess the influence of shoe aging on children running biomechanics. Fourteen children active in sports participated in a laboratory biomechanical evaluation. A new pair of shoes was provided to each participant at an inclusion visit. Four months later, the participants performed a running task and their kinematics and kinetics were assessed both with their used shoes and with a new pair of shoes identical to the first. Furthermore, mechanical cushioning properties of shoes were evaluated before and after in-vivo aging. After 4months of use, the sole stiffness increased by 16% and the energy loss capacity decreased by 18% (p<0.001). No ankle or knee kinematic adjustment was found at foot strike in used shoes but changes were observed later during stance. Running with used shoes produced a higher loading rate of the vertical ground reaction force (+23%, p=0.016), suggesting higher compressive forces under the heel and placing children at risk to experience impact-related injuries. Nevertheless, the decreased peak ankle and knee power absorption in used shoes (-11%, p=0.010 and -12%, p=0.029, respectively) suggests a lower ankle and knee joints loading during the absorption phase that may be beneficial regarding stretch-related injuries.

Subject Specific Optimisation of the Stiffness of Footwear Material for Maximum Plantar Pressure Reduction

Current selection of cushioning materials for therapeutic footwear and orthoses is based on empirical and anecdotal evidence. The aim of this investigation is to assess the biomechanical properties of carefully selected cushioning materials and to establish the basis for patient-specific material optimisation. For this purpose, bespoke cushioning materials with qualitatively similar mechanical behaviour but different stiffness were produced. Healthy volunteers were asked to stand and walk on materials with varying stiffness and their capacity for pressure reduction was assessed. Mechanical testing using a surrogate heel model was employed to investigate the effect of loading on optimum stiffness. Results indicated that optimising the stiffness of cushioning materials improved pressure reduction during standing and walking by at least 16 and 19% respectively. Moreover, the optimum stiffness was strongly correlated to body mass (BM) and body mass index (BMI), with stiffer materials needed in the case of people with higher BM or BMI. Mechanical testing confirmed that optimum stiffness increases with the magnitude of compressive loading. For the first time, this study provides quantitative data to support the importance of stiffness optimisation in cushioning materials and sets the basis for methods to inform optimum material selection in the clinic.

Immediate effects of EVA midsole resilience and upper shoe structure on running biomechanics: a machine learning approach

Background

Resilience of midsole material and the upper structure of the shoe are conceptual characteristics that can interfere in running biomechanics patterns. Artificial intelligence techniques can capture features from the entire waveform, adding new perspective for biomechanical analysis. This study tested the influence of shoe midsole resilience and upper structure on running kinematics and kinetics of non-professional runners by using feature selection, information gain, and artificial neural network analysis.

Methods

Twenty-seven experienced male runners (63 ± 44 km/week run) ran in four-shoe design that combined two resilience-cushioning materials (low and high) and two uppers (minimalist and structured). Kinematic data was acquired by six infrared cameras at 300 Hz, and ground reaction forces were acquired by two force plates at 1,200 Hz. We conducted a Machine Learning analysis to identify features from the complete kinematic and kinetic time series and from 42 discrete variables that had better discriminate the four shoes studied. For that analysis, we built an input data matrix of dimensions 1,080 (10 trials × 4 shoes × 27 subjects) × 1,254 (3 joints × 3 planes of movement × 101 data points + 3 vectors forces × 101 data points + 42 discrete calculated kinetic and kinematic features).

Results

The applied feature selection by information gain and artificial neural networks successfully differentiated the two resilience materials using 200(16%) biomechanical variables with an accuracy of 84.8% by detecting alterations of running biomechanics, and the two upper structures with an accuracy of 93.9%.

Discussion

The discrimination of midsole resilience resulted in lower accuracy levels than did the discrimination of the shoe uppers. In both cases, the ground reaction forces were among the 25 most relevant features. The resilience of the cushioning material caused significant effects on initial heel impact, while the effects of different uppers were distributed along the stance phase of running. Biomechanical changes due to shoe midsole resilience seemed to be subject-dependent, while those due to upper structure seemed to be subject-independent.