3D Printed Variable Hardness Foot Orthotics with Patient-Specific Fit

This custom-fit foot orthotic uses 3D printing, providing a clinician-to-patient manufacturing cycle that produces custom-fit foot orthotics in reduced time and lower costs. Over 29 million Americans, or 9.3 percent of the population, have diabetes. At any given moment, between 4-10 percent of diabetics have a diabetic foot ulcer. In 3-5 percent of cases, the ulcer will become serious enough that an amputation is required to save a limb or the patient’s life. Traditional pressure offloading foot orthotics manufactured from foam-box negative imprints are effective in reducing ulceration. The downside, however, is the current manufacturing practices are costly, time-consuming, and labor intensive with high material waste. Clemson University Researchers have developed a 3D-printed custom foot orthotic with patient-specific geometry and variations in material hardness. This orthotic leverages commercially available 3D-printed materials in combination with a suite of proprietary algorithms, customizing the material geometry and enabling rapid fabrication of foot orthotics at a resolution not found in standard orthotic materials.