Study of 3D printing potential in supporting the manufacturing process of shoes for people with cerebral palsy

Abstract

Currently, 3D printing is one of the most powerful manufacturing technologies. This study intends to analyse how 3D printing can support the manufacturing process of shoes' components for people with cerebral palsy. Three footwear components were considered: heel counter, metatarsalgia relief cushion, and sole. To assure the requirements for the aforementioned elements, people affected by cerebral palsy, orthopaedists, physiotherapists and experts in the production of orthopaedic shoes were consulted. Simultaneously, a WalkinSense dynamic gait test in a cerebral palsy patient was performed followed by the 3D-scanning of the feet. Subsequently, the required steps for a fully customised design were performed, resorting, when necessary, to mechanical behaviour verification through ABAQUS software; the final stage consisted in 3D printing tasks. A simple analysis to evaluate the production costs and users' satisfaction was also conducted. These case studies consist of a reliable starting point for defining new 100% customised footwear components manufacturing methodologies.