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

2. 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

3. 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 2011 39/14/2015 Q/A

4. 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

5. 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

6. 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. - 24 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

7. 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

8. 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

9. 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

10. 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

11. 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

12. Material Tested 129/14/2015 Q/A

13. Preliminary Testing Result 139/14/2015 Q/A

14. Preliminary Testing Result 149/14/2015 Q/A

15. Testing Result 159/14/2015 Q/A

16. Comparing of Models 169/14/2015 Q/A

17. 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 output584 179/14/2015 Q/A

18. 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

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

20. 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