Generative design for individual orthopaedic insoles: Optimisation of load distribution and additive manufacturing Article Swipe
Julia Schneider
,
Justus Bouffier
,
Ana Pilar Valerga Puerta
,
Diana Völz
·
YOU?
·
· 2025
· Open Access
·
· DOI: https://doi.org/10.1515/cdbme-2025-0123
YOU?
·
· 2025
· Open Access
·
· DOI: https://doi.org/10.1515/cdbme-2025-0123
Introduction: Generative Design (GD) is an intelligent process that uses algorithms to automatically create optimised, functional and material-efficient structures based on defined parameters and loads. This makes it a valuable tool for the customisation of orthopaedic insoles to suit individual load patterns. Conventional methods are frequently predicated on pressure data. However, force-based modelling has the potential to reproduce dynamic gait phases with greater accuracy. Additive manufacturing facilitates the production of such complex, customised designs. Methods: In this preliminary study, a comparison is made between different load definitions (pressure vs. force) and manufacturing constraints (additive vs. unrestricted) within GD. Pedographic pressure data is utilised to ascertain individual load distributions. The maximum value recorded during walking was utilised for the purpose of analysing the pressure load. In order to analyse the effect of force, a separate load case was defined for each gait phase, with the objective of mapping the application of force along the gait line as precisely as possible. Results: Within GD, forces can be positioned specifically for each gait phase, allowing structures to be generated with a precise fit. Conversely, pressures act over the entire surface and overlap when analysing multiple gait phases. The findings demonstrate that force-based modelling offers a more precise depiction of dynamic loads, consequently resulting in optimised insoles. Additive manufacturing constraints prove beneficial by removing the need for internal support structures, which are often hard to remove. However, thickened structures in the upper layer of the insole can compromise flexibility. Conclusion: The employment of GD facilitates the development of orthopaedic insoles that accurately reflect the patient’s individual load distribution. Future research should investigate the impact of different design choices on flexibility and biomechanical performance. In addition, the identification and evaluation of suitable materials, is crucial for determining their effectiveness in the manufacture of foot orthoses.
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Generative design for individual orthopaedic insoles: Optimisation of load distribution and additive manufacturingWork title
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2025Year of publication
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2025-09-01Full publication date if available
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Julia Schneider, Justus Bouffier, Ana Pilar Valerga Puerta, Diana VölzList of authors in order
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https://doi.org/10.1515/cdbme-2025-0123Publisher landing page
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https://www.degruyterbrill.com/document/doi/10.1515/cdbme-2025-0123/pdfDirect link to full text PDF
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goldOpen access status per OpenAlex
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| abstract_inverted_index.intelligent | 7 |
| abstract_inverted_index.investigate | 268 |
| abstract_inverted_index.manufacture | 297 |
| abstract_inverted_index.orthopaedic | 36, 255 |
| abstract_inverted_index.patient’s | 261 |
| abstract_inverted_index.preliminary | 78 |
| abstract_inverted_index.structures, | 226 |
| abstract_inverted_index.Conventional | 43 |
| abstract_inverted_index.consequently | 209 |
| abstract_inverted_index.flexibility. | 245 |
| abstract_inverted_index.performance. | 279 |
| abstract_inverted_index.specifically | 167 |
| abstract_inverted_index.Introduction: | 1 |
| abstract_inverted_index.automatically | 13 |
| abstract_inverted_index.biomechanical | 278 |
| abstract_inverted_index.customisation | 34 |
| abstract_inverted_index.distribution. | 264 |
| abstract_inverted_index.effectiveness | 294 |
| abstract_inverted_index.manufacturing | 66, 92, 215 |
| abstract_inverted_index.unrestricted) | 96 |
| abstract_inverted_index.distributions. | 108 |
| abstract_inverted_index.identification | 283 |
| abstract_inverted_index.material-efficient | 18 |
| cited_by_percentile_year | |
| countries_distinct_count | 2 |
| institutions_distinct_count | 4 |
| citation_normalized_percentile |