Improving the manufacturing of 3D printed insoles through a combined experimental and topology optimization approach

Abstract

This study integrates additive manufacturing and advanced engineering to produce lightweight, mechanically suitable insoles. The research combines experimental data and computational techniques to enhance the manufacturing process. Through mechanical testing and computational homogenization, an alternative infill pattern is identified, allowing for faster printing. Topology optimization, based on Finite Element analysis, determines an optimal material distribution for the forefoot. Validation analyses confirm the structural performance of the optimized shape. Thanks to this procedure, a time reduction up to 50% can be expected. This approach allows for an efficient and sustainable alternative for the production of insoles.