Validation Of Lattice Structural Properties
Technology
Centre for Allied Health & Pharmacy Excellence
National Healthcare Group
31 December 2024
To develop a single-layer multi-density 3D printed insole for pressure offloading in patients with Diabetic Foot Ulcers. The project demonstrated the feasibility of developing viable 3D-printed alternatives for podiatric clinical applications through an.
Year Submitted: 2024
Published Date: 31 December 2024
Tags: Technology
About this Content
Aims
To develop a single-layer multi-density 3D printed insole for pressure offloading in patients with Diabetic Foot Ulcers. The key objective is to determine if early Proof-of-Concept (POC) additive manufactured thermoplastic polyurethane (TPU) with various lattice geometry specifications is comparable to conventional multi-layer thermoplastic foam materials used in custom insoles for DFU through mechanical bench testing.
Background
Offloading modalities form a critical component in the podiatric management of diabetic foot ulcers (DFUs). Customised offloading insoles are often prescribed for patients with DFUs. Such insoles are fabricated by layering multiple single-density sheets of thermoplastic materials into a multi-density structure that provides selective offloading of high-pressure areas. In recent years, 3D printed insoles have emerged as the next frontier for orthoses product lines.
Methods
Two control specimens were selected based on conventional materials commonly used by Podiatrists in Singapore for custom-made insoles for DFUs. Five different TPU lattice structures were developed to replicate the physical properties of the materials used in the control specimens. Optimization and selection of the TPU specimen designs were conducted based on collective agreement regarding stiffness and material rebound properties. Static and dynamic mechanical bench testing were conducted to assess their mechanical properties in comparison to the control specimens.
Results
All TPU Specimens A demonstrated comparable durability and stiffness to the control specimen. TPU Specimens B demonstrated significantly different mechanical properties from the control specimen. All samples demonstrated similar durability after 100,000 cycles of dynamic compression loading. TPU Specimen Sample A5 is a viable alternative to Control Specimen A, while TPU Specimen Sample B2 exhibited poorer cushioning and force dampening properties.
Conclusion
The project demonstrated the feasibility of developing viable 3D-printed alternatives for podiatric clinical applications through an open design iterative process. By addressing the identified learning points and implementing the proposed recommendations, future research teams can enhance project efficiency, improve outcomes, and potentially accelerate the adoption of innovative materials in healthcare applications.
Lessons Learnt
The project highlighted several key areas for improvement in project management, technical execution, and collaborative processes. The feasibility of combining different TPU lattice structures to achieve desired dual-density material properties was demonstrated. More research is required to develop suitable lattice structures for localized pressure offloading. The project also highlighted the need for more thorough vendor evaluation and selection during the planning phase.
Keywords
3D printing, TPU Lattice Structure, Lattice Geometry, Foot Orthoses, Diabetic Foot Ulcers
Innovators' Details
Innovators' Details
Healthcare Cluster(s) | National Healthcare Group |
Organization(s) Involved | Tan Tock Seng Hospital, A- Star - Skin Research Institute of Singapore, EOS Singapore Pte Ltd, TÜV SÜD PSB Pte Ltd |
Platform(s) | Centre for Allied Health & Pharmacy Excellence |
Healthcare Professional Group(s) | Allied Health |
Applicable Specialty or Discipline | Podiatry |
Project Lead(s) | Melissa Susan Phua Li Ann |
Project Member(s) | Tiffany Chew Wen Ying |
Connect with this contributor!
Melissa Susan Phua Li Ann - melissa_phua@ttsh.com.sg