10a. Side view of QuadraStep Orthotics types F and C. Heel piece helps with total alignment
10b. QuadraStep Orthotics. (From left to right) Foot type F, severe pronators; Foot type A, ankle instability; Foot type C, hip and back pain; Foot type D, plantar fascitis; Foot type E, in-toe.
9a. Cavus foot (arch too high).
9b. Pronating foot. Muscles and bones where arch is supposed to be buckle over each other.
9c. Normal foot, normal arch.
8b. Insole shape cut out before sanding down the edges.
8c. Cutting the insole shape out of the vacuum form.
7a. The three forms of the 3d printed foot that we got for making insoles. The first form is on the bottom, the second is in the middle (best form), and the top one is the last.
Drawn on are the lines where we will cut out the insoles.
7b. Screen on Vacuum former.
7c. Heating of the plastic with the heater of the vacuum former.
7d. Finding the right placement of the foot on the clamp so that we could get the best form possible
6a. We had to grind down the print around the metatarsals in order for it to fit into the clamp in the vacuum former. This foot was cropped further up the leg since we wanted a form that went higher up the arch, so it did not fit as easy as our previous print.
6b. Side view
5. Two different methods of using the ABS plastic in printing side by side. Since the plastic cools differently than PLA, we had to experiment some with infill levels and printing technique.
4a. This is the cropped foot scan in the vacuum former. Notice the plastic buckling around the infill pattern.
4b. The two options for vacuum forming compared next to each other. On the top is the orthotic form and the bottom is the scan form. there are tears on the orthotic form around the toe end and the heel end.
4c. Bottom view of the printed models stuck in the formed plastic.
4d. Side view
3a. Printed second prototype model, front view. Furthest from the camera is the heel cup. On the right is the arch support.
3b. Printed second prototype model. Left side is the heel cup, arch support is the side further from the camera.
3c. Meshmixer CAD model of the second prototype.
2a.The mesh wall of the first prototype. This is what we had initially then we added thickness to it.2b. The final CAD model on Meshmixer with thickness.
2c. Bottom of the printed model of our first prototype. It was roughest on the heel, where the print was touching the printer, not just the support material. In the next print we will lift the whole thing off of the printing bed. This will use more plastic, but we think it will give the orthotic a smoother finish. This is for a right foot.
2d. Top/side view of orthotic insole. Closest to the camera is the arch support.
1. Rough Prototypes. (Right) Positive mold, scanned and 3D printed. (Middle) Paper mache rough prototype. (Left) Fabric model
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