Development of an Orthopedic Unloading Insole for Patients with Disabilities Using Additive Technologies

Abstract

Since the war in Ukraine started, the number of people with lower limb amputations has increased significantly. After prosthetics in the case of unilateral amputation of the lower limb, during further walking, the load on the healthy leg is approximately twice as much as on the prosthesis. Therefore, it is advisable to use orthopedic unloading insoles for partial relief of a healthy leg. This research looks at the advantages of manufacturing such insoles using additive manufacturing. Unlike traditional production, the production of printed insoles is automated and requires less human involvement in the processes. In traditional production, various orthopedic elements and layers of insoles use materials with different properties - EVA-pore, granitol, polymeric thermoplastic materials of different hardness. This research addresses whether orthopedic insoles printed from one material (Flex filament) would meet the requirements, if the stiffness and elasticity of the insole zones were adjusted not by selecting another material, but by adjusting the filling of layers in the Ultimaker Cura slicer when slicing the model. FDM printing technology was used on an Anet Prusa i3 printer and Flex filament.