Footprints Magazine 16

RESEARCH & TECHNOLOGY

In the Podiatry world 3D technol-ogy is nothing new. The basic technology has been around

for some 20 years, used for the production of insoles and orthot-ics. But with the advancement of 3D software the net is spreading. Bespoke shoe manufacture and 3D foot scanning in retail stores and on personal devices are here – and Podiatrists need to stay en-gaged with the progress.

As the 3D bandwagon balloons, websites like 3dprintingindustry.com and 3ders.org are providing daily news on technology, design-ers and the latest objects being printed from shoes to cars, so it is worth signing up for news. Mon-ey is also being heavily invested in development.

3D Printing Industry news recently reported that $1.25 million in seed funding lead by Silicon Valley – based Khosla Ventures, will provide United States based company Feetz the opportunity to provide custom shoes for the individual.

Feetz CEO and Founder Lucy Beard said in a media statement: “Today, we wear a shoe that’s been made and sized to fit anyone. I’m excited to bring a new reality to market by offering 7-plus billion shoe sizes–one for everyone in the world. Our shoes are not only custom fit but can be customized so that no two pairs are ever the same.”

Customers will be able to create their shoes through the Feetz app, which takes only minutes to create the 3D scan and needs only one piece of paper and three photos of each foot. The customer then chooses a design and col-our and the tailor-made shoes will be delivered in days.

Also bringing 3D technology to retail is Swedish company Volumental which recently launched their 3D scanning service, designed to ensure the customer never has to try on a range of shoe sizes again. The feet are scanned, the information stored and the right shoe selected at any time. The Scarosso store in Frankfurt will be the first to trial this new service starting around October.

But Feetz and Volumental are just two of many companies moving at a rapid pace to a digital experience or to create custom made shoes. United Nude and 3D Systems also showed their prowess at the 2015 Milan Fashion Week in May where some vibrant, outlandish designs were featured. From a podiatrists point of view, these designs would not be considered very good for the feet (see Zaha Hadid’s “Flames” photo).

The price tag for individual products is also yet to be officially finalised but it is high, with footwear company Strvct Shoe selling for around $900 a pair. For Podiatry products the development and cost is ongoing. Member Dominic Hogan recently witnessed a 3D product demonstration with a high price tag for products but saw the long-term potential.

“I was recently able to watch a demonstration of a 3D scanner at the national podiatry conference on the Gold Coast, where custom made orthoses and shoes could be made in Australia with an estimated cost of $1,000. Although research will be required and undoubtedly occur, I anticipate this area will expand with customised orthoses and shoes made to complement each other, and more importantly the patient,” he said.

"Flames" 3D fashion shoes by Zaha Hadid

It’s a 3D world

Footprints Magazine 17

RESEARCH & TECHNOLOGY

“This advancement has the potential to be especially beneficial for high risk cli-ents, or patients with partial amputations, where the or-thoses and prosthesis can be custom made to the patient’s needs, and fit perfectly into the shoe made from the same image.“

The 3D printing of shoes sounds easy but apparently this is not the case, especially for long lasting, performance shoes like runners which you do not want falling apart in the middle of a race.

One 3ders news blog reports that Nike and New Balance are using 3D printing for some designs but only for parts of the shoes such as Nike for a football cleat and New Balance for a spike cleat on a track shoe that is supposed to enhance performance. Overall expanding the materials that can be used in 3D technology needs more work as currently this is limited to a rubber-like substance.

However this will change. A recent 3ders article reported that two students from Philadelphia University – Matt Flail and Tim Ganter – may have an answer through their FOOTPRINT project which “aims to produce cutting edge footwear (running shoes) through 3D scanning, algorithmic models and 3D printing”. Not only did they want to produce custom running shoes that fit exactly, produce minimal waste and can act like an orthotic, they also wanted them to last.

“The biggest insight we found was that a huge issue with orthotics is trying to correctly fit them into footwear. You could have an orthotic that fits your foot perfectly and supports it correctly when laid flat on the ground, but if it doesn’t fit into the sneaker correctly it can do more harm than good,” Flail told 3ders.

Their research made them look at all technologies from shoe parts to prosthetic limbs and more in a bid to “rethink manufacturing”. By combining certain software packages it allowed them to manipulate the size, shape and position of the cellular structure in the materials to copy the cushioning provided by EVA foams.

“With this technique we can essentially create variable density midsoles based on specific support needs using only one material and one basic geometric structure,” he said.

“Alignment issues can finally be corrected at the source of the problem without having to produce orthotics that often don’t match up to standard sizing footwear.”

Once the team got the custom and midsole support figured out they dealt with the uppers. They teamed up with Shima Seiki knitting machines to produce a whole garment process.

“Our uppers were knit in one piece with heat shrink yarn woven into them. Once knit, the uppers were placed around the foot last and steamed, which moulded the heat shrink yarn around the foot for a perfect fit,” Flail said.

They believe this system, although still in need of further development, is on the way to providing a long lasting shoe.

Member Don Scott who has been making orthotics for over 30 years said 3D technology was the future and he was using it.

“In 2010 I was shown the 3D scanning system from Footpoint which replaced my Footmaxx Gait Analysis system, but now there are about 30 3D Scanning systems to choose from. I currently use the Herreen Radial Arm Scanner which works well for me. It is good to see there

FOOTPRINT design and concept

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RESEARCH & TECHNOLOGY

are young people out there trying to improve ways footwear and orthotics are produced,” he said.

Board member Stewart Hayes agrees with both points of view.

“It is definitely the way things are headed, but is still in its infancy stage with associated high costs. From a podiatric standpoint, 3D printing has the possibility to benefit health care practitioners and the public via custom designed innersoles, orthotics and footwear - which are just the tip of the iceberg, they are designing body parts such as knees,” he said.

“Over time, the processes will be refined for all of the products and then repeated en masse and when this

occurs, the costs will come down thus the general public will take to it.”

3D technology developer and Pedorthist Jonathan Herreen said that the next five years will see much change in the orthoses and footwear industry but warns not to spend too much on new technology as it will get out of date quickly.

“3D printing is just the start of things to come. Everybody is jumping on this technology right now…but don’t spend lots of money on expensive technology as it will be out of date shortly after you unwrap the box,” he said.

If you have any interesting 3D experiences please share them by emailing eo@podiatry.asn.au for the next Footprints.

If you can spare a few hours now and then, the clients will really appreciate your help.Anyone considering offering their services will be warmly welcomed! We can buddy you with a fellow podiatrist or you can go with a friend and add your time to CPD hours.

For inclusions and informationplease call Alexandra Viles on 0403 056 234

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