Custom Orthotic Insole Using DDM Alhassane Dienta Thomas Koser Chiagoziem Uzor 1 9/14/2015 Q/A

Table of Contents DDM Overview SME Competition Idea Generation/Insole Background Why DDM ? Design Process Prototype Testing Cost Analysis Conclusion Acknowledgements 2 9/14/2015 Q/A

DDM Overview DDM (Direct Digital Manufacturing) - Also know as “3D printing” or “additive manufacturing,” “rapid manufacturing” - Process of making 3 dimensional objects from digital file - Large variety of Materials - DDM as a game changer “the market is starting to take off, growing at a clip of up to 35 percent annually ” – Armed Forces Journal /14/2015 Q/A

The Competition - The designed product will be a device, mechanism, assembly or a subassembly representing part of another product. The resultant design should represent a fully working prototype. Any internal electronics or mechanics must be specified within the design. The geometry of the design must be defined within a three- dimensional (3-D), computer-aided design (CAD) system capable of producing robust STL files. 4 CriteriaWeight of Criteria Functionality Impact Analysis20% Cost/Benefit Analysis15% Justification of DDM Material15% Justification of DDM Process15% Component Integration15% Innovative Geometrical Features Via DDM 10% Judges Discretion10% Total100 % Judging Criteria 2012 Design for Direct Digital Manufacturing Competition Design Challenge 9/14/2015 Q/A

Idea Generation Brainstorming Customized Orthotic Insole background - Orthotic insoles are a very popular and effective way of correcting and adjusting to foot problems like over-pronation and supination which ultimately lead to plantar fasciitis, heel pain, ankle instability, heel spurs, knee pain, and lower back pain. - Millions of Customers - Our design is a custom ¾ length rigid orthotic insole to help restore regular foot bio mechanics. The ¾ length covers from the heel to the end of the metatarsals - The rigidity of the orthotic is due to its function: support and alignment. Market Research - Custom Orthotics cost between $400-$600 59/14/2015 Q/A

Why DDM ? Totally Customized to patients foot - The orthotic is customized to patients requirements due to the production procedure Cost Effective for producer - Use of less raw materials and lesser amount of man power saves a lot of production cost Unlimited Complexity - Easily matches the contours of the feet and shoes Eliminate lag time between design and production hour turn around time from doctor visit to collection of fully customized orthotic insole Enable More Flexibility - Alterations in the design can easily be made directly using the CAD package 69/14/2015 Q/A

Design Process Two Proposals – Scanning and Clay Imprint Scanning - Using a NextEngine Scanner to scan foot and send data to CAD package for adjustments 7 Scan Feet and Insole Minor adjustments in CAD Package STL file sent to Objet30 for printing Final Product in approx. 15 hours 9/14/2015 Q/A

Design Process Clay Imprint A clay imprint was performed by stepping on clay inside a wooden box, the clay was allowed to dry and using a measurement system, the foot dimensions were recorded and put into SolidWorks 89/14/2015 Q/A

Design Process SolidWorks Adjustments - With the model in solidworks, changes were made as required. The dimensions of the foot were checked for accuracy 99/14/2015 Q/A

Design Process Printing - The model is to be printed on an objet30 desktop printer. - Printer chose due to type of material required. The material used is DurusWhite430 Cure. It is a polyproylene-like material that possesses the properties required functional orthotic insoles 109/14/2015 Q/A

Testing The main objective of this test experiment is to demonstrate the difference of pressure distribution between flat insoles and custom DDM modeling insoles. Preliminary, a series of tests were done for the selection of the material. 119/14/2015 Q/A

Material Tested 129/14/2015 Q/A

Preliminary Testing Result 139/14/2015 Q/A

Preliminary Testing Result 149/14/2015 Q/A

Testing Result 159/14/2015 Q/A

Comparing of Models 169/14/2015 Q/A

Cost Analysis Table 1: Cost Analysis ExpenseCost Objet30 3D Desktop Printer$32,000 NextEngine 3D Scanner$3,000 Maintenance$5,000 Total Initial Cost$40,000 Total Material Cost $6.12/c.i. $135 Labor -$20/hr for 3$60 Orthotic Set Cost$195 Selling price$425 Profit per Orthotic$230 Amount needed to cover cost174 Max yearly output /14/2015 Q/A

Conclusion The DDM process allows for a quick transition between design and production Foot scanning is a faster, more efficient way of measuring foot dimensions Design alterations can be made easily in the CAD package 189/14/2015 Q/A

Acknowledgment 19 Capstone Advisors Stephen Johnston, Ph.D.Byungki Kim, Ph.D. 9/14/2015 Q/A

Any Questions? DDM Overview SME Competition Idea Generation/Insole Background Why DDM ? Design Process Preliminary Testing Testing Result Cost Analysis Conclusion Acknowledgements 209/14/2015