Professional Documents
Culture Documents
Abstract
Design and manufacturing strategies of custom insole shoe orthotics for diabetes patients are presented in
this paper. The computer aided reverse engineering system (CARESystem) was applied here for minimizing a
file error generated by scanning of the foot patient. The digital data imaging and communication of medicine
(DICOM) images were used for designing of complex insole orthotics. The DICOM images obtained by
HandySCANN 700TM were then converted into Stereo Lithography (STL) file (triangle based data) format. The
color mapping generated by VX element and Geomagic software yielded an accurate and smooth STL file data
of the patient's foot, and provided in the 3D solid model of orthotics shoes (insole and outsole) using curve
base surface modelling method (CBS Model). The error of an image found on the stage of 3D mesh STL file
was then edited and smoothed, prior to the 3D prototype products being processed by 3D printers. The
prototype of insole shoe orthotics was fabricated by an adaptive manufacturing machine of 3D printer
EDEN350. The comparative analysis of the insole and outsole dimensional data provided the average size of a
deviation of less than 1 mm (0.0135 - 0.0209 mm), therefore it is very promising method to deliver the custom
shoes orthotics with improved size dimensional accuracy and comfort.
Order of Authors Paulus Wisnu Anggoro, Baju Bawono, M.M Avelina, J Jamari, Athanasius
P. Bayuseno
HIGLIGHTS.doc [Highlights]
To view all the submission files, including those not included in the PDF, click on the manuscript title on your
EVISE Homepage, then click 'Download zip file'.
Research article- submitted for publication in journal of Additive Manufacturing
____________________________________________________________
*Corresponding author at the Department of Mechanical Engineering, Diponegoro University,
We confirm that the article submitted to this journal is original and has not been published
previously; that it is not under consideration for publication elsewhere. Its publication is also
approved by all authors and by the responsible authorities tacitly or explicitly where the work
was carried out. If accepted, it will not be published elsewhere in the same form, in English or in
any other language, including electronically without the written consent of the copyright-holder.
All the authors mutually agreed that it should be submitted to this journal.
1 Computer aided reverse engineering system in the design and
3
4 P.W. Anggoro1, Baju Bawono2, M.M Avelina3, J.Jamari4, A.P. Bayuseno5
5 1,2,3Department of Industrial Engineering, Faculty of Industrial Technology, University of
11
12 ABSTRACT- Design and manufacturing strategies of custom insole shoe orthotics for
13 diabetes patients are presented in this paper. The computer aided reverse engineering system
14 (CARESystem) was applied here for minimizing a file error generated by scanning of the foot
15 patient. The digital data imaging and communication of medicine (DICOM) images were
16 used for designing of complex insole orthotics. The DICOM images obtained by
17 HandySCANN 700TM were then converted into Stereo Lithography (STL) file (triangle based
18 data) format. The color mapping generated by VX element and Geomagic software yielded
19 an accurate and smooth STL file data of the patient's foot, and provided in the 3D solid model
20 of orthotics shoes (insole and outsole) using curve base surface modelling method (CBS
21 Model). The error of an image found on the stage of 3D mesh STL file was then edited and
22 smoothed, prior to the 3D prototype products being processed by 3D printers. The prototype
24 EDEN350. The comparative analysis of the insole and outsole dimensional data provided the
25 average size of a deviation of less than 1 mm (0.0135 - 0.0209 mm), therefore it is very
26 promising method to deliver the custom shoes orthotics with improved size dimensional
29
30
1
31 1. Introduction
32 The human foot frequently suffers plantar pressure distribution during performing
33 physical activities such as standing, playing, and walking. This condition may lead to injury
34 risk, which can be minimized through wearing the personal footwear with optimum fit and
35 comfort. Additionally, the human foot has very complex geometry [1]. Therefore, people
36 may have different foot shapes, of which some can suffer foot deformities caused by
37 diabetes. This disease has the highest potential to damage of the organs foot [2, 3, 4]. It
38 was described by WHO (World Health Organization) in 2009 that, at least 289 million people
39 experienced diabetes and this number may increase to 438 million people in 2030. Likewise,
40 they may suffer foot deformities such as pronation, Metatarsalgia, flat feet, neuroma, plantar
41 fasciitis, arch pain [5-8]. Moreover, these deformities make often certain pain and discomfort
42 in foot when people wearing shoes or sandal. The common complication sickness of suffering
43 diabetic is due to the foot ulceration [5]. Many factors may promote the foot ulceration, as
45 (pressure under the foot) [2,3] and an increased shear movement between the foot and the
46 shoe. If the diabetic foot is untreated, it can cause infection and ultimately the patient must
48 Further, the foot ulceration of a diabetic patient may be healed through the use of
49 custom-made foot orthoses [1], whilst the good fitted-footwear model can help prevent
50 ulcerations and amputations. Thus far, the foot orthotics can be implemented for pain relief,
51 increasing heel cushion, correction of flexible deformity, increasing foot stability and/or
52 prevention of skin breakdowns [2]. Accordingly, the custom-shoe orthotics are considered as
53 the promising method for foot pain treatment and lowering limb pathology, hence providing
54 the advantages of individualized prescription for designing and requiring the personalized
2
56 Correspondingly, much attention has been paid on development of custom foot
57 orthotics in the manufacture of shoes and sandals [3]. However, the difficulty in the design
58 and fabrication of the customized foot orthotics has been usually found due to variations in
59 orthotic device design and fabrication. Here, different aspects of design, such as insole
60 geometry [4], outsole profile/stiffness [9-10] and shoe lacing contributing to each of the foot
63 appropriate footwear for specific foot shape and biomechanical foot functioning, and this is
65 invention process for custom orthotics products are frequently made manually in a handicraft
66 industry, where technicians with high skill and having experience are needed [6,15,17]. This
67 approach leads time-consuming process, while the product with a less accuracy and worst
68 surface finish may be obtained and therefore affect significantly the discomfort in foot of the
69 patient [4].
70 The best practice method for obtaining the optimal design of custom foot orthotics is
71 to use computer aided design (CAD), which spend less time time in design and reduce in
72 manufacturing cost [9]. With the availability of CAD packages, reverse engineering (RE) has
73 now emerged as a practical method to obtain an object without data engineering drawings,
75 makes RE shorten the design time and minimize the costs involved during the process of
76 manufacturing [12]. In this case, the obtained input data of the scanning process contains the
77 detail and accurate model. Additionally, RE was successfully adopted for fabrication of the
78 insole shoe orthotics made by Eva-rubber for normal people's feet and subsequently
80 process provided the best fitted-insole product [16], which was quite similar to the surface
3
81 contour of the human foot obtained from the process of scanning. However, the typical error
82 on the surface quality of the insole shoe orthotics could be found due to differences in the
83 size of the physical model and the prototype or the lost data of the inaccurate scanning results
84 or CAD output.
86 by-layer manufacturing technology commonly employed for medical model [1, 14, 19, 20].
87 In this case, the RP model of human anatomy can be generated from high resolution digital
88 images such as computed tomography (CT), magnetic resonance imaging (MRI) and any
89 other medical scanning processes [21]. The acquired medical data set from the medical
90 scanner is subsequently segmented into 2-Dimensional (2D) pictures. These pictures are
91 usually kept in digital imagery and communication in medicine (DICOM) file format
92 (voxels), which can be acquired in 3D-biomedical computer aided design (Bio-CAD) model.
93 This Bio-CAD model can be subsequently exported into stereo lithography (STL) file for
94 fabrication of RP medical model [22]. Nevertheless, the STL file format has some
95 dimensional error, specially in the RE model of human figure. The subsequent improvement
97 Further improvement of quality of imaging data in STL file for RP medical models
98 could be attained by the accurate DICOM images [19]. The images can be converted into an
99 STL file (triangle based data) format, which is subsequently used for the manufacturing of
100 medical models using RP technologies. Since inaccuracy and rough surface of the RP model
101 was often generated due to the erroneous in STL file, a fast Fourier transform (FFT) method
102 was proposed to improve the surface contour data points, which can generate a surface and
103 STL file simultaneous by the delay triangulation method. This novel combination method
104 provided the generated STL file in accuracy and smoothness, compared to the initial STL file.
105 It is proposed in term of the present study that the STL files of the RP insole model may be
4
106 changed into the triangulation angle by this algorithm for trimming and hole-filling
107 operations.
109 engineering system (CARESystem) have been proposed to ease the acquisition of design
110 knowledge and creative ideas through reverse innovative design (RID). RID can cover a wide
111 range of 3D digital design usages, such as the 3D digitization, the 3D CAD and CAID
113 engineering) analysis and RP [1,6,14-17]. Recent studies have demonstrated the capability of
114 RID on the design of innovative footwear product [1, 6, 14-15, and 17] using the 3D image of
115 a patients foot and subsequent use this image for manufacturing shoes orthotics. Here RID
116 can develop and deliver a product with family design variation, [1] and allows adjustment of
117 a personalized shoe product. This systematic approach offers the benefits of obtaining
118 optimum results of the existing design and reducing the error rate in manufacturing products.
119 Nevertheless, there is only a limited systematic study based the RID methodology in
120 designing the customized shoes for the diabetic patient group. Thus, the design and improved
121 manufacturing process for the insole shoe orthotics based on the RE model of diabetic
122 patients is very crucial [13]. The design of specific diabetic footwear for increased comfort
124 The present study was undertaken to apply the beneficial innovative method of
125 CARESystem to produce a prototype insole and outsole fitted the foot shape of the diabetic
126 patient. The stages of this research were initiated by the foot scanning with HandySCANN
127 700TM, and STL files were verified with VX Element. Later, the PowerSHAPE 2016
128 software received a fix 3D CAD foot model with an error of less than 1 mm. The prototype
129 orthotic models were manufactured by the 3D printer machine EDEN350V. These important
5
130 steps were expected to be a standard method for constructing the custom insole orthotics with
132
135 Two women participants of age around 50-75 years were selected for this research.
136 Selection of both patients was based on consideration of the long history suffering diabetes
137 for more or less 10 years and resulted in a sickness when the patient is wearing normal
138 sandals or shoes. Similar to the previous research [3,15,17], the RID was adopted here for the
139 design process of the insole shoe orthotic, which involves an integrated digital design
140 methodology incorporating digitizing, modeling with shape parameters and product
141 definition, analysis for CAE-based product optimization and RP models [3]. The 3D data
142 acquisition process was developed by physical model and the phase of mesh processing using
144 This scanner tool produced an output data in the form of STL file, which is insensitive to
145 vibration, and does not stick to the object. The technology uses white light or laser making
146 data processing faster in the ranges of 5-10 minutes, and the utilization of lasers can produce
147 accuracy levels of upward to 5 micrometers. The 3D scanner is equipped with two cameras
148 and seven types of lasers, which can retrieve the data objects form and reach a small gap of
149 image.
150 Furthermore, the HandySCAN 700TM was chosen because it has seven intersecting laser
151 beams, which enable to speed up shooting with high precision of about 0.030 mm (0.0012
152 in). This instrument delivers a single function laser that can be employed to arrive at the
153 infantry of a gap on the object of a complicated and complex surface contour. It is also
6
154 equipped with a laser beam for the x-y value with an accuracy of up to 30 microns, and z of 5
155 microns.
156 Correspondingly, the 3D CAD data of RE foot were initially verified prior to be
157 processed further. An indispensable component of the 3D mesh foot was marked from the
158 ball of foot area to the heel (the component that is in direct touch with the insole). The
159 verification was identified by a color mapping (Fig.1). This verification of the object enabled
160 the distribution of the size difference between the data of the scanning results in the form of
162 Furthermore, the color mapping was analyzed by comparing the 3D CAD surface with 3D
163 mesh STL with the same orientation. Comparative analysis of feature on VX Element 5 and
164 PowerSHAPE 2016 was also performed in the present work. This feature took the sample
165 points on the two images being compared and then calculated for the gap between the dots
166 and displayed in shades of red to blue. Correspondingly, the software of Vx Element 5
167 provided the 3D scanning to capture data directly (real time) from 3D scanner of
168 HandySCAN 700TM which was displayed on the computer screen. This software consists of
169 modules element Vx, Vx Inspect, and Vx models. Vx Element 5 can retrieve data and
170 perform 3D scanning process to check whether the mesh processing of obtaining 3D solid
172 Additionally, the custom insoles required the high accuracy of mold, plumbing and
173 machining tools. Comparative analysis of using VX Element 5 can verify the output 3D
174 scanning. If the average deviation of less than 1 mm or 50% of the deviation is under 1 mm
175 then the data can be accepted for further processing. This means that the data of STL file are
176 fixed and could be used for the subsequent CBS (curve-based modeling) process to produce
177 insole and outsole shoe orthotic. Results of color mapping in VX Element 5 can be presented
178 in Table 1.
7
179 2.2 Modeling from 3D mesh foot to 3D solid of insole and outsole shoes orthotics
180 The 3D solid model of the foot patient in the VX Element 5 was then required for the
181 establishing process of a wireframe curve insole starting from the stage of processing oblique
182 to the generation of 3D surface editing for an existing curve. There are three modeling
183 strategies of RE widely known [1,3], namely automatic surface modeling, featured-based
184 solid modeling and CBS modeling. The CBS modeling was selected in this work because it
185 could reconstruct the 3D model of the OIS (orthotic insole shoe) with highly precise and
186 accurate result. This scheme has been successfully adopted on manufacturing insole shoe
187 orthotics for people with normal and foot deformities [6, 15-17]. Here, the CBS modeling
188 and smart features in PowerSHAPE 2016 yielded the 3D surface form using the created
189 curves and provided the reconstructed surface with high accuracy.
190 Furthermore, stages of CBS Modeling in PowerSHAPE 2016 included: (a) mesh
191 importing and pre-processes, (b) rewiring, (c) repoint, built and verification of 3d surface to a
192 solid foot with a solid doctor, (d) a 3D solid model of the foot from the mesh, (e ) oblique
193 processing, (f) foot wireframe, (g) support wire, (h) repoint wireframe curve, i) wire
194 reconstruction, (j) generating surface, (k) surface curve editing, and (l) 3D solid iso diabetes.
195 Results of the 3D solid model of OIS for the diabetic patient show with a variety of width
196 tolerances. A new optimal design of OIS with 2:00 mm width tolerance of 3D solid was set-
197 up according to the previous OIS made by RP model [15, 17]. Similarly, the outsole section
198 was performed, but wide tolerances between the insole and outsole was of about 0.75 mm.
200 A pair RP of OIS models was fabricated by an adaptive manufacturing technology with
201 3D printers Object EDEN 350 V, which contains the engine of 3D printers by Stratasys
202 released with a tray of 350 x 350 x 200 mm. This machine uses PolyJet technology that
8
203 allows the material expenditure with a thick layer up to 16 microns. It has an accuracy rate of
204 0.1 mm to 0.3 mm depending on the geometry, orientation, and size of the product.
205 Furthermore, two kinds of materials and two support of each 3.6 kg were labelled by
207 FullCure720 Transparent, and FullCure Support. Material prototype of the customized insole
208 orthotics was assigned as OIS VeroWhitePlus RGD835. The plastic material is one of the
209 materials suggested by Stratatys in the operation of Eden 350V 3D print. The material
210 properties of the polymer are presented as follow: tensile strength of 50-65 MPa, elongation
211 at break of 10-25%, modulus of elasticity of 2000-3000 MPa, flexural Strength of 75-110
212 MPa, flexural modulus of 2200 to 3200 MPa, HDT (heat deflection temperature), OC @ 1.82
213 MPa 45-50 C, water absorption of 1.1-1.5%, Shore hardness of 83Scale-86 D, Rockwell
214 hardness Scale M of 73-76, 1:17 to 1:18 polymerized density (g/cm3), 0:23 to 0:26% ash
216
217 3. Results
218 The multiple images of 3D foot models resulted from the output scanning, verification of
219 the VX Element and prototype OIS products are given in Figures 2-6. The form of 3D mesh
220 foot (Fig.2) was subsequently justified for insole shoe and outsole orthotic models. The VX
221 software-Element 5 directly connected to the computer and Handyscan 700TM could
222 greatly simplify and speed to optimize 3D solid model of RE (Fig.3). Table 1 presents
223 results of the standard deviation for both pairs of legs diabetic patients with an average
224 deviation less than 1 mm. Output file of RE was then converted into a pair of insole and
225 outsole pair using methods CBS modeling[1] with a variation of width tolerance. The optimal
226 width tolerance of the previous research [15,17] employed in this study provided a good fit
9
227 with the patient's feet on the second insole, of which assembly with wide legs of 2.00 mm
229 Moreover, the RP models of the insole, outsole and the foot of a patient could be formed
230 in terms of all solid 3D images of insole, outsole and foot, and subsequently verified by the
231 open source system software [Autodesk Netfabb 2017]. The use of software made significant
232 improvements and optimizing STL file before being put into the 3D printer machine. The
233 need for this optimizing STL file was mainly directed to the failure reduction, when the file
234 was inserted into the machine tool (EDEN 350V). Consequently, the manufacturing products
236 The RP models of OIS product were then verified for the precise dimensional size and
237 suitability of fit between the physical model and the 3D CAD models using a measuring
238 instrument vernier caliper with 0:01 mm tolerance. The measurements of RP models were
239 performed by determination of area dimensions in the CAD drawings (the measured point)
240 given in Figure 7. The results of dimensional verification of RP models in CAD drawings and
241 prototype products of OIS show an average size difference of less than 0.5mm (Tables 2 and
242 3). Also, there is the relatively small deviation in dimensional size for prototype having
243 deviated by more than 1mm. This means between the CAD drawings of scanning results
244 and color mapping of a prototype are in good fitting of a dimensional model. Therefore,
245 the results of the prototype can be confirmed in accordance with existing CAD
246 drawings.
247
248
249
250
251
10
252 4. Discussion
253 The present study has demonstrated the excellent method in the design of OIS product
254 through the 3D mesh foot obtained from the 3D scanning process. The process was carried
255 out by the infrared laser beam of HandySCANN 700TM on the foot surface required at least
256 ten minutes for a pair of legs. The results of the 3D scanning process are in form of 3D
257 mesh STL files. The 3D mesh STL or triangle mesh is a set of the custom surface of
258 dots that form a small triangle. This small triangle can be linked to form a custom
259 geometry of an object. Data triangle mesh is more comfortable for RE because the
260 shaped surface can be outfitted with the foot in term of cloud points not dots. This
261 procedure allows the RE to be quicker because it does not need to be converted into
262 dots point cloud of STL. The 3D scanning process was performed in the present
263 research to get data insoles of the base up to the ankle area. Foot area is an important
264 part because it is a direct contact with the footwear. Arches and the part of foot surface
265 were required to form the 3D insole orthotics, which can be obtained from the 3D
266 scanning process. The results of the 3D mesh STL file could be in conformity with the
267 original shape of the foot. Correspondingly, the level of accuracy below the tolerance
268 limit of 1 mm could be achieved in the present study. This important file can be
269 employed in the subsequent machining with CNC machine for an insole or outsole
271 Further, the CAD technology has some limitations for image processing with organic
272 contour shape of the foot such as diabetic patients with high-risk scale. This condition
273 resulted in frequent errors when doing image editing foot using the solid feature. The CAD
274 software cannot extract the surface of the foot 3D mesh perfectly with the features of shrink
275 wrap. Nevertheless, the benefits of CAD can be explored for feature comparison analysis
11
276 between the 3D mesh and 3D CAD insole. The results of this analysis can allow researchers
278 Additionally, the function of Vx Element 5 can simplify the analysis data of RE with
279 PowerSHAPE2016. The 3D mesh can be changed by automatic surfacing clicking on surface
280 features into the 3D surface of the mesh so that it can be read and analyzed in PowerSHAPE
281 2016. The benefit of Vx Element 5 to process the RE model of patients with foot deformities
282 has been also reported previously [6, 8,15-17]. In the present research, the process of
283 extracting the 3D surface of the mesh to solid by this software yielded an average deviation in
284 less than 1 mm. Therefore the program enables to enter the optimal surface mesh data for the
286 Based on the color mapping, it can be seen that the results of RE are green, which indicates
287 that there is a small deviation. It appears that the improvement in the patient's leg 1 produces
288 an average deviation of 0.1395833 to 0.0937500 mm with an error range -0.3756 to 0.6413 in
289 left foot and right foot of -0.3707 mm to 0.5926 mm (Table 1). The color mapping for patient
290 2 indicates an average deviation of 0.1326389 up to 0.1451389 mm with an error range left
291 foot -1.6146 to 0.6066 mm and the right foot of - 0.7644 to 0.5640 mm (Table 1). The results
292 of RE are appropriate and can be further processed in an RP machine using 3D printer
293 EDEN350V to obtain optimal new OIS products. The mean deviation image RE results in
294 Table 1 gives the figure a deviation of less than 1 mm. This indicates that the level of
295 accuracy of the image described in this paper is high and automatic surfacing results are in
297 Once 3D models of the fixed foot are obtained, the insole and outsole shoe orthotics can
298 designed based on CBS modeling [1, 6, 14, 15 and 17]. The 3D model of the new insole and
299 outsole shoe orthotics can be successfully produced by CBS modeling. Also the CAE
300 analysis with a width tolerance of 0.75 mm frequently provides the optimal design of insole
12
301 product for diabetic patients [6, 17]. In this study, the optimal design was then constructed
302 using the 3D print EDEN350V yielding the prototype foot, insole and outsole of special
304 The verification process of size dimensions in the image STL file, 3D CAD models and
305 prototype RP models were conducted similarly to the previous RP medical models [21]. The
306 outcomes of this study equally demonstrate the value of the dimensional error of less than 1
307 mm, while the mean error in the initial STL models was reported in the range of 0.38mm and
308 0.16 mm [21]. In this work, notwithstanding, the mean error of the STL smooth model shows
309 a tolerant at values of 0.201 mm and 0.268 mm for patient number 2 and 0.254 mm and 0.214
310 mm for patient number 1. This indicates that the application CARESystem on the design of
311 insole shoe orthotics can deliver a good custom orthotics similar to the medical models [21].
312 The similarity lies in the average value of the dimensional error generated in. STL smooth
313 image model of the RP model. Accordingly, the results of this study can be applied in shoes
314 and sandal industries for producing a low cost of custom insole and outsole orthotics for
315 diabetic patients. The CARESystem strategy is very promising for design application of
316 all patients with foot deformities such as flat foot, high heel, syndrome Morton's
318
319 5. Conclusions
320 CARESystem was applied in this study providing the customized special orthotic
321 products that are specifically designed and manufactured for diabetics mellitus patients with
322 high risk. OIS product results have precision surface contours and dimensional fit of the foot
323 of patients, which can provide a good level of comfort and reduce pain in foot patients. Also
324 CARESystem in the future can be made for designing custom shoe orthotics for some
325 disabled patients foot (flat feet, high heel, Morton's neuroma syndrome, Metatarsalgia and
13
326 other foot deformities). This system can be expected to resolve the design and manufacturing
327 problems faced by sandal and shoe industries in an effort of development of customized
329
330 Acknowledgements
331 The authors would like to gratefully thank to: Mr. Rieky L Liberman and Mrs. Stefani as
332 Managing Director and Head of Engineer PT. Trimitra Wisesa Abadi, Mr. Y Bambang
333 Nugroho as the managing director of PT. Hankook Delcam Indonesia, Mr. V. Ariyono, as
334 Chairman of the Department of Industrial Engineering and Mr. A.Tonny Yuniarto, as Head
336 Technology, University of Atma Jaya Yogyakarta, and Tribology Laboratory of the
338 provided full support in the form of infrastructure CAD, CAM, CAE 3D HandySCAN and
340
341
342 5. References
344 Raffaeli, CAD tools for designing shoe lasts for people with diabetes, Computer
346 [2] A.S. Salles, D.E. Gyi, The specification of personalized insoles using additive
348 [3] X. Ye, H. Liu, C. Lei, C. Zhiyang, X. Pan, S. Zhang, Reverse innovative design - an
349 integrated product design methodology. Computer Aided Design 40 (2008) 812-820.
350 [4] T.X. Qiu, E.C. Teo, Y.B. Yan, W.Lei, Finite Element Modeling of a 3D Coupled
14
352 [5] A.W.L. Yao. Application of 3D Scanning and Reverse Engineering Technique for
353 Quality Control for Quick Response Product. Int. J. Adv. Manuf. Technol. 26 (2005)
354 1284-1288.
355 [6] P.W. Anggoro, B. Bawono, P. Policharpus, J. Jamari, A.P. Bayuseno. Finite element
356 modeling of the insole shoe orthotic for foot deformities, International Conference on
357 Engineering Tribology and Applied Technology (ICETAT 2016), (2016), November
358 4-6.
359 [7] P.W. Anggoro, B. Bawono, A. Wicaksono, J. Jamari, A.P. Bayuseno, Reverse
360 innovative design from 3D mesh to 3D model insole shoe orthotic, Procedings of
366 [9] The American Orthopaedic Food& Ankle Society, Volume 30, Issue 1, Winter 2016.
367 [10] B. Vicenzino, Foot orthotics in the treatment of lower limb conditions: a
369 [11] P.O. Mogeni, A/P. Vickeswari. Duraijajah, S. Gobee, Design and development of a
370 CAD/ CAM System for foot orthoses. ISBN: 978-0-9891305-4-7 2014 SDIWC:
371 91-99.
372 [12] Oancea, Ivan N.V, Pescaru R. Computer aided reverse engineering system for
373 costumized product. Annals of MTeM for 2013 & Proceedings of the 11th
15
375 [13] R. Pescaru, G. Oancea, I. Badan. Parametric modelling of shoe lasts using reverse
377 11.
378 [14] J.D. Chapman, S. Preece, B. Braunstein, A. Hhne, C.J. Nester, P. Brueggemann, S.
379 Hutchins, Effect rocker shoe design features on forefoot plantar pressure in people
380 with and without diabetes. Journal of Critical Biomechanics 28 (2013) 679-688.
381 [15] U. Luigi, G. Claudia, The role of footwear in the prevention of diabetic foot problem,
382 J. The Diabetic Foot. Medical and Surgical Management, Contemporary Diabetes,
384 [16] Z. Xia, Application of reverse engineering based on computer in product design.
385 International Journal of Multimedia and Ubiquitous Engineering 2014; Vol.9, No.5 :
386 343-354
387 [17] P.W. Anggoro, B. Bawono, A. Wijayanto, J. Jamari, A.P. Bayuseno. Parameter
388 optimatizion of strategies at CNC Milling Machines Rolland Modela MDX 40R CAM
389 against surface roughness made insole shoe orthotic Eva Rubber Foam. International
391 [18] P.W. Anggoro, B. Bawono, A.A. Antony, J. Jamari, A.P. Bayuseno, Determining
392 optimal toolpath strategy in the manufacture of ortothic insole shoe made from eva
393 rubber for diabetes patients. Proceding of 1st International Joint Conference on
395 [19] E. Piperi, L. M. Galantucci, J. Kaani, E. Shehi and T. Spahiu, From 3D foot scans to
16
399 [21] A. Manmadhachary, Y. Ravi Kumar, L. Krishnanand, Improve the accuracy, surface
400 smoothing and material adaption in STL file for RP medical models. Journal of
402 [22] H.I.Othman, Role of computer aided design and computer aided manufacturing
403 technology in prosthetic implant restorations. Int. J. Dental Clin. 4 (2012) 22-34.
406 [24] Ay. Mustafa, T. Kubat, C. Delilbasi, B. Ekici, H.E. Yuzbasioglu, S. Hartomacioglu,
409 [25] C.Y. Huang, L.J. Luo, P.Y. Lee, J.Y. Lai1, W.T. Wang, S.C. Lin, Efficient
410 segmentation algorithm for 3D bone models construction on medical images. J. Med.
412 [26] J. Santolaria, R. Jimenez, M. Rada, F. Loscos, Error compensation method for
413 improving the accuracy of biomodels obtained from CBCT data. Med. Eng. Phys. 36
415 [27] D.V. Nguyen, N.V. Quang, L.H. Le, E.H.M. Lou, Validation of 3D surface
416 reconstructionof vertebrae and spinal columnusing 3D ultrasound data-a pilot study.
418 [28] H. Ameddah, M. Assas. Bio-CAD reverse engineering of free-form surfaces by planar
420 [29] W.E. Lorensen, H.E. Cline, Marching cubes: a high resolution 3D surface
17
422 [30] D. Wu, H. Tian, G. Hao, Z. Du, L. Sun, Design and realization of an interactive
423 medical images three dimension visualization system. 3rd International Conference on
425 [31] D.J. Yoo. Three-dimensional human body model reconstruction and manufacturing
426 from CT medical Image Data using a heterogeneous implicit solid based approach.
428 [32] C.S. Wang, W.H.A. Wang, M.C. Lin, STL rapid prototyping bio-CAD model for CT
430 [33] C. Denga, H. Lin, Progressive and iterative approximation for least squares B-spline
431 curve and surface fitting. Comput. Aided Design 47 (2014) 32-44.
432 [34] J.D. Janisse, W. Coleman. Pedothric care of the diabetic risk category. In: The
434 [35] Clinical Best Practice Guidelines. Assessment and Management of Foot Ulcers for
435 People with Diabetes, Second Edition. Registered Nurses Association of Ontario;
437 [36] L.A. Lavery, D.G. Armstrong, R.P. Wunderlich, J. Tredwell, A.J. Boulton,
440 [37] D.G. Armstrong, E.J. Peters, K.A. Athanasiou, L.A. Lavery, Is there a critical level of
441 plantar foot pressure to identify patients at risk for neuropathic foot ulceration? The
443 [38] S. Bus, J.S. Ulbrecht, P.R. Cavanagh. Pressure relief and load redistribution by
444 custom-made insoles in diabetic patients with neuropathy and foot deformity. Clinical
18
446 [39] D. Brown, J.J. Wertsch, G.F. Harris, J. Klein, D. Janisse. Effect of rocker soles on
447 plantar pressures. Archives of Physical Medicine and Rehabilitation 85 (2004) 81-86.
448 [40] C. van Schie, J.S. Ulbrecht, M.B. Becker, P.R. Cavanagh, Design criteria for rigid
450 [41] P.R. Cavanagh, A.J.M. Boulton, P. Sheehan, J.S. Ulbrecht, G.M. Caputo, D.G.
451 Armstrong. Therapeutic footwear for people with diabetes. The Journal of the
453 [42] M. Germania, M. Mandolinia, M. Mengonia, C. Nesterb, R. Raffaeli. Tools for design
454 and validation of shoe lasts for diabetic patients. Footwear Science 4 (2012) 221-241.
455
19
FIGURES CAPTION
Figure 1 Ball of foot indicated by the blue line of the 3D mesh foot area
Figure 2 The 3D Mesh of STL file for foot: (a) patient no. 1; (b) patient no. 2
Figure 4 Top view and isometric 3D new design of asembly foot & insole of diabetic patient
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Tables
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; (b) patient 2
Table 2 Measured dimensions of CAD models and prototype models of OIS for patient 2
Table 3 Measured dimensions of CAD models and prototype models of OIS for patient 1
Table 1
Mean Standard
Sample Point Point Error range
Patient Foot deviation deviation
point calculates interpolated
(mm) (mm) (mm)
Left 263.005 37.857 225.148 0.1395833 -0.3756 to 0.6413 0.24792
1
Right 236.766 37.56 199.26 0.0937500 -0.3707 to 0.5926 0.18333
Left 373.552 38.773 334.779 0.1326389 -1.6146 to 0.6066 0.35417
2
Right 303.396 36.835 266.561 0.1451389 -0.7644 to 0.5640 0.28611
Table 2
CERESystem provide a standard method for designing the insole shoe orthotics
Reverse innovative design (RID) yields the 3D CAD of orthotics
The ease of manufacturing for custom insole shoe orthotics with lower production cost
The systematic of CERESystem leads accuracy in dimension of products