Data

PLA Supported Printed Insole: After talking to Professor Munoz,  we decided to try to model an insole based off of the idea of the QuadraStep insoles (one part, flexible plastic, heel and toe plate).  When printing with PLA, it is clear that the insole was too solid and not flexible enough. So, we have decided to experiment with printing in different plastic of varying flexibilities.

Vacuum Forming: We tested the vacuum forming on two options for our use of the vacuum former. We used the cropped scan of the foot (like the one that we used for the rough prototype fig.1) as well as the printed second prototype of our orthotic.   When vaccum forming, the cropped foot scan worked much better for multiple reasons, mostly because we could lay it on the flat side.  This made it easy to remove from the plastic after the forming was finished without damaging it.  in addition, the orthotic prototype had empty space under it.  This resulted in the plastic wrapping around the underside and tearing, breaking the seal that the vacuum had, and creating a less accurate form.  The only issue that we had with the foot scan was that there was melting and drooping of the plastic around the infill.  We believe that this can be solved in multiple ways : using a more dense infill and a plastic with a higher melting point. Fig. 4

Second Prototype: This orthotic prototype fits the food (Lynne Right) much better than the last.  The issue of the arch support coming across the food was solved when we chose to model the prototype off of the full foot scan rather than the cropped one.  The arch support still seems high, but we hope to discuss that with the orthotic specialist that we meet though city as our campus. Once again, we still need to get an orthotic design we are happy with before we move onto testing durability/strength/flexibility. Fig. 3

First Prototype: We know this does not work because it does not fit the intended foot correctly (Lynne Right).  The arch support (left edge of orthotic) does not come far enough across the foot to be effective and comfortable.  Since this is not even a possibly useable orthotic, no testing is needed to determine strength or durability. See Fig. 2