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The research group of PTE 3D and their market partner, CorvusMEd Kft orthopaedic aid manufacture have cooperated in analysing the usability and developing a market model of the Leo Insole design software developed by Leopoly Kft.

What is Leo Insole?

Leopoly Kft. is a software development company with a US-Hungarian presence, based on 3D technologies and working for the international market. They have visited the 3D Printing and Visualization Centre of the University of Pécs (PTE3D Centre) for the first time in autumn 2023. During the visits, Leopoly Kft. experts were able to learn about the PTE3D Centre's printing portfolio, engineering services, as well as the work of the clinic's biomechanics laboratory and related research groups.

The experts of Leopoly Kft. have developed a personalised insole designer software that is the first to be compatible with beta-testing, and also able to run in a browser. The software was named Leo Insole.

The software is aimed at companies that manufacture and sell comfort and medical insoles. These companies could design the personalised insoles of their customers via the online software on a user-friendly platform, based on locally done 3D sole scans. The complete models could be 3D printed locally or outsourced to be done quickly and efficiently.

However, for future sales of the software, they needed a medical and engineering cooperation not connected to the University, where the usability of the project could be validated and feedback could be collected from real users. The PTE3D research groups has conducted their clinical studies with a group of 60 people, testing the usability of the design software (Leo Insole) and the effects of wearing unique insoles manufactured with the help of the software.

How were the tests done?

Leopoly Kft. has made the software and a sole scanner available for the PTE3D Centre. After obtaining an ethical licence, the researchers of the biomechanical lab have included 60 volunteers in the study. The first step, the volunteers had both of their soles scanned. The samples obtained were sent to the employees of CorvusMed Kft, who then used the software to design personalised insoles for the participants, which were then printed by a company specialised in 3D printing with MJF (Multi Jet Fusion) technology, in cooperation with Leopoly Kft. The completed products were given to the participants by the researchers of the biomechanical lab.

When receiving the insoles, the participants have also filled a survey about their expectation about the product. Every participants had to undergo a complex motion analysis examination before starting to wear the insoles, to determine the actual walking image. The motion analysis examination was repeated a month later to gain a real image about whether the insoles have caused a measurable change in the walking image. Participants were asked to fill a survey again, to learn about their experiences with wearing the insoles. Based on this data, most of the participants were satisfied with their soles and would wear in the future regardless of the future. Furthermore, very important and valuable feedback were received regarding the future optimalization and improvement of the design.

Why are 3D printed insoles more effective compared to other insoles available on the market?

Insoles made by 3D sole scanning and 3D printing offer many advantages over insoles made by traditional methods like 2D scanning, impression foam sampling or modular hand-made methods. 3D scanning also offer higher accuracy and more details. 3D scanners can capture the full geometry of the sole, including small surface details and possible deformities that would not show up on traditional, 2D methods. This allows for the insole to not only be personalised based on length, width, or arch height, but based on every detail of a person’s sole.

3D technologies also offer flexibility, since the design can be optimised digitally, and the manufacturing process can be quickly personalised. After a new scan, the design of the insole can easily be updated, and a new version can be printed without having to restart the entire process. On the other hand, traditional methods usually take longer, and the human factor plays a larger role in making the insole. Hand-made modular insoles cannot always guarantee the same level of accuracy or flexibility as a digitally moderated 3D manufacturing process.

3D scanning and printing allows for a better fit, higher personalisation levels and a more efficient manufacturing process, while using the advantages of modern technologies for precision and personalisation.

Long-term goals

Based on the research results obtained during the tests - the results of the motion analysis tests conducted by the researchers, the feedback of the test participants and the technicians using the software - the goal of the development company (Leopoly Kft.) is to further develop the innovative system and, with the cooperation of the contracting parties, to develop the business model of the service and to launch the product on the market.