Studying Maximum Plantar Stress per Insole Design Using Foot CT-Scan Images of Hyperelastic Soft Tissues

3D-printed medial arch supports of varying hardness versus a prefabricated arch support on plantar pressure: A 1-month randomized crossover study in healthy volunteers

BACKGROUND

Foot orthoses are commonly used as a noninvasive treatment to relieve foot pain. The custom full-length insoles with various materials and designs have been studied for their effectiveness in reducing plantar pressure. However, few studies have been conducted with respect to custom medial arch support on the relationships between material hardness and measured plantar pressure and level of comfort.

OBJECTIVES

To evaluate the effects of the hardness of custom medial arch supports on plantar pressure and comfort perception.

STUDY DESIGN

Randomized crossover study.

METHODS

Two custom silicone medial arch supports of varying hardness (A and B) were fabricated using 3D printing technology and tested in 12 healthy volunteers against a commercially prefabricated arch support (C). The volunteers wore three medial arch supports in a random order, one month for each arch support with 3-4 days of washout period before wearing the next one. The plantar pressure was measured and analyzed according to each foot zone: forefoot, midfoot, and hindfoot, comparing before intervention, immediately after intervention, and 1 month after intervention. The comfort perception was assessed by collecting volunteer feedback with a questionnaire after using each medial arch support.

RESULTS

After 1-month intervention, both 3D-printed and prefabricated medial arch supports demonstrated significantly higher average pressure in the midfoot ( P < 0.001), whereas significantly lower average pressure in the forefoot ( P < 0.001) and hindfoot ( P = 0.014, 0.026, and 0.018 for A, B, and C, respectively), compared with those before intervention. There were no significant differences in plantar pressure distribution between the 3D-printed and prefabricated medial arch supports. However, the 3D-printed medial arch supports resulted in better comfort than the prefabricated arch support.

CONCLUSIONS

The material hardness had no apparent effect on plantar pressure distribution. The three medial arch supports showed reducing plantar heel pressure. Further research is needed to investigate the potential effect of 3D-printed silicone medial arch supports on reducing foot pain in patients.

Photocurable and elastic polyurethane based on polyether glycol with adjustable hardness for 3D printing customized flatfoot orthosis

Orthopedic insoles is the most commonly used nonsurgical treatment method for the flatfoot. Polyurethane (PU) plays a crucial role in the manufacturing of orthopedic insoles due to its high wear resistance and elastic recovery. However, preparing orthopedic insoles with adjustable hardness, high-accuracy, and matches the plantar morphology is challenging. Herein, a liquid crystal display (LCD) three-dimensional (3D) printer was used to prepare the customized arch-support insoles based on photo-curable and elastic polyurethane acrylate (PUA) composite resins. Two kinds of photo-curable polyurethanes (DL1000-PUA and DL2000-PUA) were successfully synthesized, and a series of fast-photocuring polyurethane acrylate (PUA) composite resins for photo-polymerization 3D printing were developed. The effects of different acrylate monomers on the Shore hardness, viscosity, and mechanical properties of the PUA composite resins were evaluated. The PUA-3-1 composite resin exhibited low viscosity, optimal hardness, and mechanical properties. A deviation analysis was conducted to assess the accuracy of printed insole. Furthermore, the stress conditions of the PUA composite resin and ethylene vinyl acetate (EVA) under the weight load of healthy adults were compared by finite element analysis (FEA) simulation. The results demonstrated that the stress of the PUA composite resin and EVA were 0.152 MPa and 0.285 MPa, and displacement were 0.051 mm and 3.449 mm, respectively. These results indicate that 3D-printed arch-support insole based on photocurable PUA composite resin are high-accuracy, and can reduce plantar pressure and prevent insoles premature deformation, which show great potential in the physiotherapeutic intervention for foot disorders.

A Study on the Effects of Lateral-Wedge Insoles on Plantar-Pressure Pattern for Medial Knee Osteoarthritis Using the Wearable Sensing Insole

Patients with knee osteoarthritis have a unique plantar-pressure pattern during walking, and lateral-wedge insoles are one of the treatment options. Participants were randomly assigned to either the lateral-wedge insole group or the ordinary insole group. The Visual Analog Scale (VAS), Western Ontario and McMaster Universities Osteoarthritis Index (WOMAC), and plantar-pressure test scores were evaluated at the baseline and at 20 weeks. Plantar pressure data were collected using a pressure insole with 89 sensing locations. In the ordinary insole group, the function and total WOMAC scores decreased significantly (function score, 24.8 (baseline) to 16.5 (week 20); total score, 34.9 (baseline) to 24.6 (week 20)). During walking, the transverse width of the center of pressure as a percentage of foot width (%Trans) significantly increased in the ordinary insole group (baseline, 6.3%; week 20, 14.8%). In addition, the values of partial foot pressure as a percentage of body weight (%PFP) on the forefoot (baseline, 30.3%; week 20, 39.2%) and heel (baseline, 28.1%; week 20, 16.9%) also increased significantly in the ordinary insole group. Significant group-by-time interaction effects were observed for partial foot pressure per body weight in the forefoot (p = 0.031) and heel (p = 0.024). In the ordinary insole group, the plantar pressure on the heel significantly decreased (p = 0.011) and that on the forefoot significantly increased (p = 0.023). In contrast, plantar pressure remained stable in all regions in the lateral-wedge insole group. Thus, lateral-wedge insoles may protect against plantar pressure deterioration in patients with knee osteoarthritis.

Custom Shoe Sole Design and Modeling Toward 3D Printing

This study introduces a design procedure for improving an individual’s footwear comfort with body weight index and activity requirements by customized three-dimensional (3D)-printed shoe midsole lattice structure. This method guides the selection of customized 3D-printed fabrications incorporating both physical and geometrical properties that meet user demands. The analysis of the lattice effects on minimizing the stress on plantar pressure was performed by initially creating various shoe midsole lattice structures designed. An appropriate common 3D printable material was selected along with validating its viscoelastic properties using finite element analysis. The lattice structure designs were analyzed under various loading conditions to investigate the suitability of the method in fabricating a customized 3D-printed shoe midsole based on the individual’s specifications using a single material with minimum cost, time, and material use.

The Design of Individual Orthopedic Insoles for the Patients with Diabetic Foot Using Integral Curves to Describe the Plantar Over-Pressure Areas

Identification of over-pressure areas in the plantar side of the foot in patients with diabetic foot and reduction of plantar pressure play a major role in clinical practice. The use of individual orthopedic insoles is essential to reduce the over-pressure. The aim of the present study is to mark the over-pressure areas of the plantar part of the foot on a pedogram and describe them with high accuracy using a mathematical research method. The locally over-pressured areas with calluses formed due to repeated injuries were identified on the patients' pedograms. The geometric shapes of the over-pressure areas were described by means of the integral curves of the solutions to Dirichlet singular boundary differential equations. Based on the mathematical algorithm describing those curves, the computer programs were developed. The individual orthopedic insoles were produced on a computer numerical control milling machine considering the locally over-pressured areas. The ethylene vinyl acetate polymers of different degrees of hardness were used to produce the individual orthopedic insoles. For the over-pressure areas, a soft material with a hardness of 20 Shore A was used, which reduces the pressure on the plantar side of the foot and increases the contact area. A relatively hard material with a hardness of 40 Shore A was used as the main frame, which imparts the stability of shape to the insole and increases its wear life. The individual orthopedic insoles produced by means of such technology effectively reduce the pressure on the plantar side of the foot and protect the foot from mechanical damage, which is important for the treatment of the diabetic foot.

Effects of insoles adapted in flip-flop sandals in people with plantar fasciopathy: a randomized, double-blind clinical, controlled study

OBJECTIVE

To evaluate the effects of insoles adapted into flip-flop sandals on pain and function in individuals with plantar fasciopathy (PF).

DESIGN

Randomized, double-blind controlled study.

SETTING

Physiotherapy clinic of the Faculty of Health Sciences of Trairi, Federal University of Rio Grande do Norte, Santa Cruz, Brazil.

SUBJECTS

Sixty-six patients of both genders with PF were randomized into two groups: sandal insole group (SI; n = 34), which received a pair of custom flip-flop sandals with insoles covered with smooth synthetic leather; and plain sandal group (PS; n = 32), which received an identical pair of flip-flop sandals, but without the insoles.

INTERVENTIONS

Patients were instructed to wear the flip-flops for 12 weeks for at least 4 hours/day.

MAIN MEASURES

Pain (visual analogue scale-VAS) in the morning and at the end of the day were considered primary outcomes. Function (Foot Function Index-FFI and Foot and Ankle Ability Measure-FAAM) and functional capacity (6-minute walk test-6MWT) were considered secondary outcomes. The outcomes were evaluated at baseline and immediately after the intervention by a blind assessor.

RESULTS

Between-group differences were observed in terms of morning pain (mean difference (MD) = -1.82 cm; 95% confidence interval (CI) = -3.3 to -0.3; P = 0.016) and function (MD = -0.10; 95% CI = -0.19 to -0.01; P = 0.023) after the interventions with the SI group showing superior improvements in comparison to the PS group.

CONCLUSION

The use of insoles adapted in flip-flop sandals for 12 weeks was effective at improving pain and function in individuals with PF.

LEVEL OF EVIDENCE

1b.

The Effect of Arch Height and Material Hardness of Personalized Insole on Correction and Tissues of Flatfoot

Flat foot is one of the common deformities in the youth population, seriously affecting the weight supporting and daily exercising. However, there is lacking of quantitative data relative to material selection and shape design of the personalized orthopedic insole. This study was to evaluate the biomechanical effects of material hardness and support height of personalized orthopedic insole on foot tissues, by in vivo experiment and finite element modeling. The correction of arch height increased with material hardness and support height. The peak plantar pressure increased with the material hardness, and these values by wearing insoles of 40° were apparently higher than the bare feet condition. Harder insole material results in higher stress in the joint and ligament stress than softer material. In the calcaneocuboid joint, the stress increased with the arch height of insoles. The material hardness did not apparently affect the stress in the ankle joints, but the support heights of insole did. In general, insole material and support design are positively affecting the correction of orthopedic insole, but negatively resulting in unreasonable stress on the stress in the joint and ligaments. There should be an integration of improving correction and reducing stress in foot tissues.