Additive manufacturing is praised in the shoe sector for creating opportunities for customization. Custom shoes go further than collecting your favorite shade palette and fashion. They can provide good support and comfort to wearers that require it.
Imre Patterson a young boy residing in California was born with a femoral discrepancy. This means that one leg is shorter than the other. This condition has not prevented Imre from having an engaged and dynamic lifestyle.
But it has developed some difficulties, as old foam orthotics are usually extremely heavy. Imre’s parents chose to examine the possibility of additive manufacturing to make personalized 3D printed orthotics. This was in a way to make things simple for their son.
The family contacted Dinsmore Inc., an Irvine, CA based additive manufacturing services provider with almost three decades of practice. After listening to Patterson’s family and what it was looking for, the team started working on creating a custom orthotic.
This orthotic was to be suitable for additive manufacturing. Maximizing PA12 and HP’s Multi Jet Fusion technology, the service agency 3D printed the first variant of a lattice midsole. The midsole was both easier and more long-lasting than Imre’s more old foam boot.
3D printed footwear was effective and was made by the use of HP’s technology. But it was not a good fit for Imre’s energetic lifestyle. Dinsmore decided to solve this by using Carbon’s Digital Light Synthesis technology.
The next variant of the midsole was, therefore, 3D printed by the use of a DLS 3D printer and an elastomeric polyurethane-based material.
The structure midsole was also tailored to match with footwear offered by Decker Brand that were 3D scanned at the SEMA Garage by Conner Morris. Through the scan data Dinsmore team created a CAD print of the midsole. This midsole was then fitted and attached to Imre’s TEVA and UGG shoes.