Computer-aided reverse engineering system in the design and production of orthotic insole shoes for patients with diabetes

Figures & data

Figure 1. Ball of foot as indicated within the blue line of the 3D mesh foot area.

Table 1. Color mapping analysis and verification of scanning from 3D mesh to 3D CAD model of insole and outsole shoe orthotics for (a) patient 1 and (b) patient 2

					Mean deviation	Error range	Standard deviation
Patient	Foot	Sample point	Point calculates	Point interpolated	(mm)	(mm)	(mm)
1	Left	263.005	37.857	225.148	0.1395833	−0.3756 to 0.6413	0.24792
	Right	236.766	37.56	199.26	0.0937500	−0.3707 to 0.5926	0.18333
2	Left	373.552	38.773	334.779	0.1326389	−1.6146 to 0.6066	0.35417
	Right	303.396	36.835	266.561	0.1451389	−0.7644 to 0.5640	0.28611

Figure 2. The 3D mesh of the STL file for the feet of (a) patient no. 1 and (b) patient no. 2.

Figure 3. Output file of the RE foot patient in STL file format.

Figure 4. Top view and new isometric 3D design of the foot assembly a insole for two diabetic patients.

Figure 5. Top views of the RP model prototype assembly for two diabetic patients.

Figure 6. Prototype of the RP model for insole shoe orthotics.

Table 2. Measured dimensions of CAD models and prototype models of OIS for patient 2

	Right foot			Left foot
Point	Prototype measurement (mm)	CAD measurement	Differences in size (mm)	Prototype measurement (mm)	CAD measurement	Differences in size (mm)
A	94.53	94.26	0.27	94.62	94.55	0.07
B	76.19	76.26	0.07	72.90	73.03	0.13
C	66.49	66.23	0.26	57.93	58.56	0.63
D	215.67	216.54	0.87	221.33	221.58	0.25
E	102.10	102.09	0.01	102.29	102.62	0.33
F	97.35	97.69	0.34	96.31	96.45	0.14
G	76.19	76.37	0.18	72.48	72.32	0.16
H	251.67	251.64	0.03	251.33	251.59	0.26
I	90.65	90.56	0.09	86.99	87.27	0.28
J	97.32	97.10	0.22	98.13	97.51	0.62
K	82.72	82.96	0.24	76.61	76.76	0.15
L	35.59	35.71	0.12	39.83	39.84	0.01
M	243.33	243.64	0.31	241.67	242.00	0.67

Average error in .STL smooth model 0.201 mm (right foot) and 0.268 mm (left foot).

Table 3. Measured dimensions of CAD models and prototype models of OIS for patient 1

	Right foot			Left foot
Point	Prototype measurement (mm)	CAD measurement	Differences in size (mm)	Prototype measurement (mm)	CAD measurement	Differences in size (mm)
A	86.34	86.14	0.2	88.92	88.69	0.23
B	58.87	58.65	0.22	63.75	63.68	0.07
C	49.84	49.30	0.54	51.08	50.92	0.16
D	215.50	216.43	0.93	217.00	213.98	3.02
E	90.20	90.17	0.03	94.69	94.70	0.01
F	60.05	59.94	0.11	66.95	67.00	0.15
G	69.8	69.40	0.40	72.80	72.77	0.03
H	235.05	234.47	0.58	233.20	233.10	0.1
I	85.98	85.72	0.26	83.57	83.35	0.22
J	82.61	82.79	0.18	94.69	94.54	0.15
K	59.68	59.10	0.58	62.89	62.92	0.03
L	52.62	52.11	0.51	65.67	65.52	0.15
M	226.20	226.47	0.27	224.50	225.10	0.6

Average error in .STL smooth model 0.254 mm (right foot) and 0.214 mm (left foot).

Figure 7. Area of foot measurement points: insole and outsole orthotics.

Figure 8. Insole of shoes manufactured for two patients.

Figure 9. Outsole of shoes manufactured for two patients.

Figure 10. Shoe lasts of shoes manufactured for two patients.

Figure 11. Shoes with orthotic insoles as manufactured.

Figure 12. Steps of fabricating an orthotic insole shoe using the developed system CARES.

Table 4. The content of the questionnaire for diabetic patients

No.	Attribute	Importance				Satisfaction				Expectation
	Prototype of OIS (orthotic insole shoe)
1	Good dimension and material	1	2	3	4	1	2	3	4	1	2	3	4
2	Interesting shape	1	2	3	4	1	2	3	4	1	2	3	4
	Use of OIS (orthotic insole shoe)
3	Lightweight	1	2	3	4	1	2	3	4	1	2	3	4
4	Easy to initially use	1	2	3	4	1	2	3	4	1	2	3	4
5	Comfortable to use	1	2	3	4	1	2	3	4	1	2	3	4
6	Easy to use while walking	1	2	3	4	1	2	3	4	1	2	3	4
7	Protecting the foot while walking	1	2	3	4	1	2	3	4	1	2	3	4
8	Good stability	1	2	3	4	1	2	3	4	1	2	3	4
9	Rigid	1	2	3	4	1	2	3	4	1	2	3	4
10	Durability	1	2	3	4	1	2	3	4	1	2	3	4

Table 5. The results of the questionnaire given to diabetic patients

No.	Attribute	Importance		Satisfaction		Expectation
		Patient 1	Patient 2	Patient 1	Patient 2	Patient 1	Patient 2
	Prototype of OIS (orthotic insole shoe)
1	Good dimension and material	3	3	4	4	3	3
2	Interesting shape	4	4	3	4	3	3
	Use of OIS (orthotic insole shoe)
3	Lightweight	3	3	4	4	3	4
4	Easy to initially use	3	3	4	4	4	4
5	Comfortable to use	4	4	4	4	4	4
6	Easy to use while walking	3	3	4	4	4	4
7	Protecting the foot while walking	4	4	4	4	4	4
8	Good stability	3	3	4	4	4	4
9	Rigid	3	3	4	4	4	4
10	Durability	4	4	4	4	4	4