METHODS AND DEVICES FOR DESIGNING FOOTWEAR

专利摘要:
Methods and devices for designing custom footwear are described. A custom footwear design device may include a data collection system, a data processing system, and a manufacturing system, the manufacturing system including an additive manufacturing device. A method of designing a custom footwear may include receiving user data, generating a user model, identifying problems in the user model, determining corrective aspects, generating a custom footwear model, and producing the custom footwear. include custom footwear.
公开号:BE1022215B1
申请号:E2014/0581
申请日:2014-07-29
公开日:2016-03-01
发明作者:Tom Cluckers
申请人:Materialise N.V.；
IPC主号:

专利说明:

Methods and devices for designing footwear
DESCRIPTION
BACKGROUND OF THE INVENTION
This application relates to the field of footwear, in particular to methods and devices for designing custom-made footwear.
Classic footwear is not made to the size of the user. On the contrary, this footwear is designed on the basis of general characteristics that usually apply to most feet. As a result, footwear is often not comfortable for the user and / or they are unable to correct or prevent problematic foot-related conditions.
In an effort to correct various foot problems, footwear inserts (for example, insoles) were used. Unfortunately, in most cases the inserts for footwear are not better suited to the foot of a user than the original footwear. Therefore, "custom made for the user" footwear inserts have been developed with a view to correcting or preventing problems. These footwear inserts do not take into account the real foot of the user in any way.
Unfortunately, custom-made footwear inserts were usually limited to custom-made insoles intended for use in otherwise non-custom-made footwear. Since other aspects of the non-customized footwear, such as, for example, the body, midsole and outer sole, were not made to the size of the user, the efficiency of the custom-made footwear inserts remained limited.
Furthermore, the design of custom-made footwear is often a manual, time-consuming, error-prone and expensive operation. As such, large-scale production of such customized footwear posed a problem. After all, every custom-made footwear insert is made to measure by definition. These and other factors have limited the availability and efficiency of custom-made footwear and have increased their cost.
Accordingly, there is a need for improved methods and devices for designing and producing custom-made footwear.
Summary
This application describes methods and devices for designing custom-made footwear.
In one embodiment, a method for creating a piece of footwear based on a user model comprises: receiving user data associated with a user; generating a user model based on the received user data; determining one or more corrective aspects based on the user model, generating a custom-made footwear model that contains a certain corrective aspect, and creating a piece of footwear based on the custom-made footwear model.
In a number of embodiments of the method, the piece of footwear is created by means of an additive manufacturing technique.
In a number of embodiments of the method, the user data comprises one or more of: data about the foot pressure, data about the step, data about the body or image data.
In a number of embodiments of the method, determining one or more corrective aspects is additionally based on statistical data.
In a number of embodiments of the method, the statistical data comprises a statistical form model.
In a number of embodiments of the method, the piece of footwear is one of a shoe, a boot or a sandal.
In a number of embodiments of the method, the customized footwear model includes at least one of a bend line pattern, a zone of changed thickness, or a cellular structure.
In a number of embodiments of the method, the piece of footwear includes at least one of a bend line pattern, a zone of changed thickness, or a cellular structure.
In a number of embodiments of the method, the piece of footwear is configured with a view to changing a biomechanical action of the user's foot.
In a number of embodiments of the method, the piece of footwear is configured with a view to improving a static weight distribution of a user's foot.
In another embodiment, a device configured for the purpose of creating a piece of footwear includes: a data collection containing models of footwear templates and executable software; a sensor configured to create user data, and a processor in data communication with the data set and the sensor, the processor configured to execute the software and cause the device to: receive of user data associated with a user; generating a user model based on the received user data; determining one or more corrective aspects based on the user model, generating a customized footwear model that contains a certain corrective aspect; and creating a piece of footwear based on the customized footwear model.
In a number of embodiments of the device, the piece of footwear is created by means of an additive manufacturing technique.
In a number of embodiments of the device, the user data comprises one or more of: data about the foot pressure, data about the step, data about the body or image data.
In a number of embodiments of the device, the processor is configured to execute the software and further leading the device to: determine one or more corrective aspects based on statistical data.
In a number of embodiments of the device, the statistical data comprises a statistical form model.
In a number of embodiments of the device, the footwear is one of a shoe, a boot or a sandal.
In a number of embodiments of the device, the customized footwear model includes at least one of a bend line pattern, a zone of changed thickness, or a cellular structure.
In a number of embodiments of the device, the piece of footwear includes at least one of a bend line pattern, a zone of changed thickness, or a cellular structure.
In a number of embodiments of the device, the piece of footwear is configured with a view to changing a biomechanical action of the user's foot.
In a number of embodiments of the device, the piece of footwear is configured with a view to improving a static weight distribution of a user's foot.
Brief description of the drawings
Figure 1 illustrates an embodiment of a system of customized footwear.
Figure 2 illustrates a method for designing custom-made footwear.
Figure 3A illustrates a graphical user interface of an example of a data collection system.
Figure 3B illustrates a graphical user interface of an example of a component of a footwear design.
Figure 4 illustrates custom-made footwear.
Figure 5A illustrates custom-made footwear.
Figure 5B illustrates certain aspects of a microstructure.
FIG. 6A-6B illustrate an insole (footwear part) produced by an additive manufacturing technique.
Figure 7 illustrates an example of an additive manufacturing device.
Figure 8 illustrates an example of a computer device.
Detailed description of certain embodiments of the invention
Tailor-made footwear can be beneficial for the treatment of a wide range of known foot conditions. For example, the pronation of the foot (that is, the sagging of the foot while standing, walking, and walking) can lead to swelling and problems with the Achilles tendon. Tailor-made footwear can be designed to correct or improve static and dynamic foot pressure to treat pronation. The made-to-measure footwear can, for example, improve the support under the medial arch of the foot and can limit the ability of the footwear to bend in certain directions.
As another example, a bunion can be treated with custom-made footwear that reduces medial strain and provides user-specific support for the hallux (the big toe). Other conditions can also be treated by means of tailor-made footwear, for example plantar fasciitis, arthritis, poor blood circulation, metatarsalgia, patellofemoral knee pain, pelvic inflammation, Achilles tendon tendinitis, repetitive overload injury and other conditions known in the art.
In addition to the treatment of existing negative foot conditions, tailor-made footwear can also contribute to the prevention of injuries and the development of foot conditions. Tailor-made footwear can, for example, reduce stress-related injuries of the foot, ankle, knee, back, etc. by better weight distribution with the impact of foot contact, or by changing the way the foot in the foot course of dynamic movements comes down and rotates. Similarly, custom-made footwear can prevent movement in a certain direction (for example, the movement of a folding ankle) and promote movement in another direction (for example, rolling the forefoot during transition movements).
In addition, custom-made footwear can improve the biomechanical performance (for athletes, for example). For example, custom-made footwear can change the impact angle of a foot during dynamic activities, such as walking, which in turn can increase the overall speed of the runner. People in the field know that custom-made footwear has many other advantages.
Tailor-made footwear can be designed using data about the physical properties or attributes of a specific user, so-called "static" user data. For example, the shoe size and the static foot pressure (when standing for example) can be measured.
Tailor-made footwear can also be designed using dynamic user data, such as dynamic foot pressure measurement results. The dynamic pressure on a user's foot can be measured, for example, in the course of dynamic foot activities such as walking, walking, jumping, descending, turning, rolling, cradling, etc. When designing custom-made footwear, almost all functional biomechanical measurements are used.
Tailor-made footwear can also be designed using non-user-specific data, for example statistical data on the population. For example, the average shape of a certain shoe size can be statistically determined or be available in other cases in existing statistical data sets. Furthermore, the statistical means for these and other physical foot features may have associated statistical parameters such as distributions, standard deviations, variances, and other parameters known in the art. In this way, knowing a single foot feature associated with a user, for example the shoe size, can lead to the use of numerous associated statistical foot features (e.g., shape, size, etc.).
Finally, as described in more detail in the following, said data types and other data can be used to create customized footwear, for example, user-specific anatomical aspects, user-specific orthopedic needs, user-specific treatment needs, user-specific performance requirements, and other information known in the art.
User-specific static data
User-specific static data can be used when designing customized footwear. Different types of user-specific static data can be generated by different methods.
For example, basic user-specific data can be used to design custom-made footwear such as age, gender and weight. Some basic data related to the user may be objective data (such as height and weight) while other basic data related to the user may be subjective (such as activity level and user preferences).
User-specific static data can be specific to a body part. For example, data related to the foot of a specific user may be: the length of the foot, the width of the foot, the height of the arch, the location of the arch, the shape of the foot, the footprint, the shoe size, the flexion or extension of the foot in different directions, inversion and eversion of the foot, strength of the different foot muscles, bone alignment, pronation, supination, and other characteristics known in the art. In a number of cases, physical characteristics can be determined by means of manual physical measurements (with, for example, a measuring tape), while other physical characteristics are determined by means of digital measuring systems (for example, a digital scale).
Given the complexity of the shape and composition of different body parts, for example the foot, more accurate methods of recording data can be beneficial.
User-specific data can, for example, be generated using one or more image sensors, such as video cameras or cameras. Different types of cameras can be used here, including classic digital cameras with a single image sensor or stereoscopic cameras with two or more image sensors. Classic digital cameras, including mobile cameras, can be used to take a multitude of images of an object, a body part for example, from different angles to provide depth and a three-dimensional structure. The multitude of images of the body part, for example a foot (or other anatomical aspects such as the ankle, a calf, etc.) can be analyzed by means of, for example, a computer system to thus obtain three-dimensional (3D) user-specific data. determine, for example, a 3D model.
By way of example, U.S. Patent No. 8,226,261, entitled "3D Face Reconstruction from 2D Images", which is incorporated in its entirety in this text as a reference, describes methods for determining 3D models of, for example, a face, from a multitude of two-dimensional (2D) images. Similarly, the PCT patent application WO 2012/129252, entitled "Digital 3D Camera Using Periodic Illumination", which is incorporated in its entirety in this text as a reference, describes methods for using a digital camera and projected light patterns to construct three-dimensional models determine by means of two-dimensional image data. Additionally, two or more cameras can be used simultaneously to generate three-dimensional user-specific data. By way of example, U.S. Patent No. 5,532,368, entitled "Method and Device for Producing 3D Model of An Environment," which is incorporated herein in its entirety as a reference, describes methods of using a mobile stereo camera system to determine three-dimensional models. Accordingly, image sensors can be used with the aforementioned and other methods known in the art to capture two-dimensional user-specific data and to build up user-specific three-dimensional models based on the two-dimensional data.
In a number of cases, mobile devices (e.g., smartphones and tablets) may contain stereoscopic image sensors, which may be referred to as "3D cameras". Such devices may have the capability of capturing image data and creating three-dimensional data or a three-dimensional model without having to rely on an independent processing system for further processing.
In addition, more advanced camera systems, for example the "Kinect", available from the Microsoft Corporation (Redmond, Washington, USA) offer image data including in-depth information. Similarly, specially developed 3D scanners using image sensors can be used, for example the "Gotcha" 3D scanner from 4DDynamics (Antwerp, Belgium) or the MakerBot® Digitizer ™ (New York, New York, USA).
An advantage of using a device for recording images, such as one or more cameras, to determine user-specific data is that such devices are generally digital, portable, and relatively inexpensive. As such, systems for designing custom-made footwear may be wholly or partially portable (e.g., the imaging system). The portability of the system increases the possibilities of using such a system in different circumstances.
Other devices can also be used to generate three-dimensional user-specific data. For example, optical scanners, scanners that use lasers, and other scanning systems known in the art can be used to scan a body part, for example a foot, and to create a three-dimensional model associated with the scanned body part. An advantage of, for example, a laser-based optical scanning system is that it can create highly accurate three-dimensional models of the object to be scanned. However, such scanning systems may be less portable and also more expensive than an image-based modeling system such as the aforementioned. : Medical imaging techniques can also be used to generate two-dimensional and three-dimensional user-specific data. For example, to generate two-dimensional and three-dimensional user-specific data, x-ray scans, computed tomography (CT) scans, positron emission tomography (PET) scans, magnetic resonance imaging (MRI), ultrasonic scans, and other medical imaging techniques known in the art may be employed . These can in turn be used to create a two-dimensional or three-dimensional model of a body part such as a foot. In particular, certain types of medical imaging may also provide additional details regarding internal anatomical aspects and functions, such as bone structures, bone alignment, the placement of muscles and ligaments, the placement of cartilage, and others as known in the art. The design of customized footwear can take these aspects into account in a favorable way.
Sensors can also be used to determine user-specific data. For example, a pressure sensitive tape can record the distribution of pressure associated with a user's footprint. That is, a user may stand on a pressure sensitive tape for the purpose of generating a plurality of readings of the pressure associated with the user's static footprint.
In a number of cases, a plurality of forms of measurement, imaging, and detection can be performed on a molded, molded, or other imprint of a body part of a user, e.g., a foot model. This possibility opens the door for designing custom-made footwear without the user having to be in the place of, for example, the scanning equipment. In other cases, a user may generate data, for example two-dimensional or three-dimensional image data, using his own equipment, for example his camera-equipped mobile telephone or video camera, and subsequently supply this data to a data processing system intended to be customized design footwear made by that user. In this way the user does not have to go to the place where other aspects of the tailor-made footwear system are located. For example, the user may provide basic information about himself (e.g., height, weight, and preferences information) along with a plurality of self-generated two-dimensional image data to a remote service that uses the data to tailor that user's footwear. design and produce.
In general, said methods for generating user-specific static data can be used to create detailed two-dimensional or three-dimensional models of a body part of a user such as a foot. These models can in turn be used to design custom-made footwear. To this end, computer-aided design (CAD) or computer-aided manufacturing (CAM) software, such as software commercially available from Matérialisé USA (Plymouth, Michigan, USA), can be used to process user-specific data and to create custom-made footwear designs.
User-specific dynamic data
Tailor-made footwear can also be designed using dynamic user data. User-specific dynamic data include data collected with regard to user dynamic movements such as walking, walking, jumping, falling, turning, rolling, cradling, etc. One means of measuring user-specific dynamic data is a pressure-sensitive mat or tape, configured to measure pressure data over time and to deliver that data to, for example, a processing system. Such pressure sensitive bands can be relatively large, so that they can measure more than one foot in the course of the user's movement. In addition, sufficiently large pressure sensitive bands can measure features such as the step, the step, the foot contact, the ball of the foot, the rotation of the foot, and others as known in the art.
Systems that measure the dynamic pressure distribution on a foot are described, for example, in European patent applications EP0970657A1 and EP1127541A1, which are incorporated in their entirety in this text as a reference. Based on the measurement of: dynamic pressure on a foot in the course of movement, assumptions can be made about the movement of different parts of the foot. Finally, customized footwear can be designed based on the measurements of the dynamic pressure.
Pressure sensitive devices can be used in combination with other devices for recording dynamic data, such as user portable force sensors, motion detection sensors, image sensors and the like. For example, force sensors can be mounted on a user to take the force when the user moves dynamically. In a number of cases, mobile devices including motion-sensitive sensors can be used to collect motion data to be analyzed. Thus, as described above, a user can use his own mobile equipment not only to record user-specific static data (such as elementary data about the user and still images) but also to record user-specific dynamic data, for example forces of motion data. In a number of cases, the user can use his own mobile equipment to collect all the data needed to design custom-made footwear.
Motion registration sensors can be used to collect and analyze dynamic user data. By way of example, systems with computer-identifiable targets attached to a user and a monitoring system can track the targets with a view to generating user-specific dynamic data.
Measurements of dynamic data can be combined. For example, pressure sensitive bands and / or motion sensors can be used in addition to image recording equipment, so that the dynamic data can be compared to images of a user in action. For example, a high-speed camera can record the movement of a user's body part, such as a foot, while pressure-sensitive sensors collect data about the movement of the foot, the impact, etc.
Statistical data about body parts
Tailored footwear can also be designed using statistical data about body parts, for example population data. For example, a specific shoe size can be associated with various traits that are statistically predictable based on the analysis of population data. As mentioned above, a specific shoe size can be associated with statistical distributions over the length and width of an "average" foot of that size, and with the placement of various anatomical aspects such as the toes, the heel, the bow, etc. of a foot of that size.
In a number of cases, a statistical shape model (Statistical shape model, SSM) can be built based on a multitude of user-specific data on two-dimensional or three-dimensional body parts. A statistical shape model can be used, for example, to analyze the shape of a body part of a user or to create a model of the body part of the user for the purpose of designing custom-made footwear. Such statistical form models can be particularly useful when the available user-specific data is incomplete or inaccurate. Additionally, a statistical shape model of a body part such as a foot can be used to provide an automatic analysis of two-dimensional or three-dimensional image data of that body part.
User model
A user model can be generated based on one or more user-specific static data, user-specific dynamic data, statistical data, or other data as described in this text. In a number of cases, the user model can be a two-dimensional or three-dimensional model of a body part of a user, for example a foot of a user. In a number of cases, the user model may contain graphical information, such as a two-dimensional or three-dimensional depiction of a user's body part, or may instead be a data model with different attributes or characteristics relating to the user. In a number of cases, the user model contains both graphic data and attribute data in the same model. For example, a user model may include a visual presentation of a user's body part based on image data, as well as pressure data associated with different points on the visual presentation based on user-specific dynamic data.
In a number of cases, such as when little or no user-specific dynamic data was received, the user model can mainly be generated based on statistical data or on a template, or both. The user model can, for example, be supplemented with static or dynamic data, for example pressure data. This data can improve the model with a view to designing suitable custom-made footwear.
Footwear parts
Tailor-made footwear can contain various footwear parts, such as, for example, a body, an insole, a midsole and an outer sole.
The body can be that part of the footwear (such as a shoe) that surrounds the side and top of a user's foot. The body may contain parts such as the support for the heel, the support for the ankle, elastic band, laces, belts, tongue, and other structures known in the art. In a number of cases, the body of the footwear may comprise two or more parts that can be selectively bonded to one another by a user, for example by means of laces or belts.
An insole can be the inner part of the footwear (such as a shoe) that is in direct contact with the bottom (and to some extent the side) of a user's foot. A custom made insole can be a fixed (that is, permanent) part of a shoe, or in some cases a removable part of a shoe.
A midsole can be a footwear part between the insole and the outer sole which, in a number of cases, is primarily a shock-absorbing part. In a number of cases, the midsole can be designed to primarily support a significant part of a user's weight and to provide shock-absorbing properties of the footwear in use. In other cases, the midsole may be designed with a view to improving the aspects found in the insole and / or outer sole.
The outer pouch can be the outer part of the footwear, and can be designed to come into contact with the ground. In a number of cases, the outer stuff can also be called a tread. The outer pouch can be designed with, for example, structures and / or texture to get the footwear to grip on a wide range of surfaces. Additionally, the outer pouch can be designed to protect a user's foot from punctures or other harmful intrusions. As described above, the midsole can additionally be designed with a view to improving the aspects found in the midsole.
In a number of cases, a footwear (such as a shoe) can contain one or more of the aforementioned parts. Different combinations of these footwear parts are meant by this. Specific footwear, for example, can have a body, an outer zipper and an insole, but no midsole. In a number of cases, one or more of the body, the insole, the midsole and the outer sole may be permanently bonded to each other. By way of example, even though they are designed separately, and even though they may contain different materials, a body, an insole, a midsole and an outer sole can still be produced as an integral footwear.
In a number of cases, one or more of the body parts, the insole, the midsole and the outer sole are tailor-made footwear parts that are designed at least in part on the basis of the different types of data described above. In a number of cases, one or more of the aforementioned footwear parts may contain one or more materials and / or structures or corrective aspects. For example, a midsole may contain various three-dimensional structures that are intended to absorb shocks while reducing the overall weight of the footwear.
Corrective aspects in footwear
Tailor-made footwear can contain one or more corrective aspects, specifically designed to influence the adjustment and / or behavior of the footwear during wear and use by a user.
In a number of embodiments, corrective aspects are intended to correct anatomical or biomechanical problems with the user's foot. For example, a user may have a relatively high arc, which causes problems in the area of the support with normal footwear. As such, custom-made footwear can include a custom-made footwear part, for example an insole, which adds support under the high arch for better distribution of the user's weight in the footwear.
In a number of embodiments, corrective aspects are intended to prevent injury and not to correct an injury or anatomical problem. For example, dynamic data can be used to determine the balance of a foot during movements (for example, when walking). The equilibrium determined in this way can be compared to the optimal equilibrium sequences that can be derived from dynamic or statistical data from typical users, such as athletes, who perform at high levels for long periods without sustaining injury. Corrective structures can thus be designed to promote a better balance of the foot during movements and thus to prevent injury.
In other embodiments, corrective aspects are intended to improve performance and not to correct an existing or potential problem. It has been found, by way of example, that characteristics related to the initial foot contact during walking are related to the running speed of athletes. To this end, dynamic data can be collected to determine the characteristics of the initial contact of a user's foot while walking, for example, the zone of landing (e.g., heel, midfoot, forefoot), the ratio between the resp. forces acting on the central and radial parts of the foot, the maximum forces when landing, the speed of unrolling the foot, and other characteristics known in the art. On the basis of this provision, a tailor-made footwear part, for example a medium-sized zone! or an outside mess, are configured with a view to changing the initial contact of the user's foot while walking so as to improve his walking speed and / or efficiency.
Corrective aspects may include, for example, zones of reduced or increased thickness in a shoe portion. For example, a custom made insole can have a zone near the arch with increased thickness to provide additional support for the arch.
Corrective aspects can also show bending lines, ribs, incisions, strips or other patterns that facilitate the bending of a footwear part in certain directions or, on the contrary, inhibit it. The number, thickness, direction and relative proximity of such corrective aspects can influence the tendency of that part of the footwear to bend in certain directions. For example, an outer sack may include ribs and cutouts in a particular direction in view of increasing the tendency of the outer sack to deflect the bend in a selected direction and to counteract the tendency to bend in an undesired direction.
Corrective aspects can also contain relatively simple or relatively complex microstructures. Examples of microstructures are, for example, rays, gratings, regular 3D grids, regular or irregular open or closed cell structures, foam or spongy formations, trusses, springs, shocks, triklinic, monoclinic, orthorombic, hexagonal, trigonal, tetragonal or cubic structures, and others known in the art. Microstructures can influence the characteristics of a footwear part, for example the mechanical behavior of a footwear part. Moreover, microstructures can exert an influence on other characteristics of a footwear part, such as elasticity, viscoelasticity, rigidity, wear resistance and density. Note that the prefix "micro" in "microstructure" refers primarily to the ability to tailor the structure at a very low level. This means no limitation on the size of the microstructures as a whole. Structures that contain microstructures can indeed be made in any size and in any shape.
In addition to the shape of the microstructure, the position and size of the structures (or their components) can influence the characteristics of the footwear.
In addition, characteristics of connection points between microstructures can also influence the characteristics of the footwear. For example, the thickness of a connecting point can exert an influence on the mechanical properties of a specific footwear part. In a number of cases, connection points may, for example, be selectively thickened or diluted to influence the manner in which the footwear member responds to different loads in different directions.
In a number of cases, corrective aspects can be merged or combined to give more complex features to a footwear section. For example, in addition to varying the thickness of a particular footwear portion, the various layers that make up the thickness of that portion may contain unique corrective aspects, e.g., microstructures or others as described above.
In a number of cases the corrective aspects may be on the surface of a footwear part. By way of example, surface aspects such as texture, patterns, lines or others as described above can be used to provide the user of custom-made footwear with more grip, more feel, more comfort, etc.
In a number of cases, one or more of the aforementioned corrective aspects can be arranged in zones associated with footwear parts. Such zones can be configured with a view to influencing different mechanical properties of the footwear in different zones. In a number of cases a whole footwear part can be one zone, and in other cases a footwear part (for example an insole) can comprise one or more zones. In a number of cases, a zone can contain a single corrective aspect, for example a microstructure.
All in all, the selection, ordering and physical properties of various corrective aspects in footwear can be used to correct and counteract a user's biomechanical characteristics, prevent injuries, and / or promote better performance.
Additive manufacturing
Tailor-made footwear can be produced through additive manufacturing techniques. Numerous additive manufacturing methods are known in the art, for example, stereolithography (SLA), selective laser sintering (SLS), selective laser melting (SLM), fused deposition modeling (FDM), et al.
Stereolithography (SLA) is an additive manufacturing technique that is used for layer after layer "printing" of three-dimensional objects. An SLA device can use, for example, a laser to cure a photo-reactive substance by means of emitted radiation. In a number of embodiments, the SLA device guides the laser through a surface of a photo-reactive substance such as, for example, a hard-hair photopolymer ("resin") for the purpose of layer-by-layer forming of an object. For each layer, the laser beam follows a cross-section of the object on the surface of the liquid resin, whereby the cross-section hardens and solidifies and is deposited on the layer below. Upon completion of a layer, the SLA device lowers a production platform with a distance equal to the thickness of a single layer and deposits a new surface of uncured resin (or a similar photoactive material) on the previous layer. A new pattern is followed on this surface and a new layer is formed in this way. By repeating this process layer after layer, a complete three-dimensional component can be formed. Selective laser sintering (SLS) is another additive manufacturing technique that is used for printing three-dimensional objects. SLS devices often use a powerful laser (for example a carbon dioxide laser) to "sinter" small particles of plastic, metal, ceramic or glass powder into a three-dimensional object. As with SLA, the SLS device can use a laser to scan sections on the surface of a powder bed in accordance with a CAD design. Similarly to SLA, the SLS device can lower a production platform with the thickness of one layer after a layer has been completed, and supply a new layer of material so that a new layer can be formed. In some embodiments, an SLS device may pre-heat the powder to make it easier for the laser to raise the temperature during the course of the sintering process. Selective laser melting (SLM) is another technology of additive manufacturing that is used for printing three-dimensional objects. Like SLS, an SLM device generally uses a powerful laser to selectively melt thin layers of metal powder to form solid metal objects. Even though SLM is a process similar to SLS, it is different because it generally uses materials with much higher melting points. When forming objects by means of SLM, thin layers of metal powder can be distributed using different coating mechanisms. As with SLA and SLS, a production surface moves up and down to allow individual layers to be formed.
Fused deposition modeling (FDM) is another additive manufacturing technique in which a three-dimensional object is produced by extruding small grains of, for example, a thermoplastic material from an extrusion head to form layers. In a typical arrangement, the extrusion head is heated to melt the raw material upon extrusion. The raw material then hardens immediately after extrusion from a cup. The extrusion head can be moved in one or more directions by means of suitable machinery. In a similar way as the mentioned techniques of additive manufacturing, the extrusion head follows a path that is controlled by CAD or CAM software. The component is also built in a similar way from bottom to top, layer after layer.
Using additive manufacturing techniques, objects can be formed using different materials such as polypropylene, thermoplastic polyurethane, polyurethane, acrylonitrile-butadiene-styrene (ABS), polycarbonate (PC), PC-ABS, PLA, polystyrene, lignin, polyamide , polyamide with additives such as glass or metal particles, methyl methacrylate-acrylonitrile-butadiene-styrene copolymer, resorbable materials such as polymer-ceramic composites, and other similar suitable materials. Commercially available materials can be used in a number of embodiments. These materials can be, for example: the materials of the DSM Somos ™ series 7100, 8100, 9100, 9420, 10100, 11100, 12110, 14120 and 15100 from DSM Somos; Stratasys materials ABSplus-P430, ABSi, ABS-ESD7, ABS-M30, ABS-M30I, PC-ABS, PC-ISO, PC, ULTEM 9085, PPSF and PPSU; the line materials Accura Plastic, DuraForm, CastForm, Laserform and VisiJet from 3-Systems; aluminum, cobalt chrome and stainless steel materials; maraging steel; nickel alloy; titanium; the PA materials line, PrimeCast and PrimePart materials and Alumide and CarbonMide from EOS GmbH.
Tailor-made footwear, including a tailor-made footwear part, can be produced through additive manufacturing techniques. Advantageously, an additive manufacturing device can "print a whole footwear part or a full piece of footwear into a single, integral workpiece." For example, a device of additive manufacturing, instead of making individual insoles, midsole and outer soles, can create a custom-made footwear part layer after layer with non-homogeneous corrective aspects (e.g., microstructures) in each individual layer. 3D printing can thus offer a much higher degree of customization of footwear than traditional production techniques.
Furthermore, three-dimensional printing of custom-made footwear can advantageously reduce the number of materials and individual pieces that must be produced to achieve a desired footwear design. In addition, additive manufacturing techniques can exploit the benefits of a wider range of materials to produce tailor-made footwear in comparison to traditional production techniques.
In a number of cases, techniques of additive manufacturing can improve traditional production steps. For example, footwear parts may contain surface textures, patterns, structures, etc. that may be useful for traditional production steps such as gluing, fusing, or otherwise bonding parts together. In a number of cases, the surface textures can be created by microstructures. As another example, a footwear part produced by an additive manufacturing technique can be finished with a production layer with a high porosity and / or a specific texture with a view to improving the adhesion of that part to another footwear part with the help of glue or other adhesive.
Description of a number of exemplary embodiments
Figure 1 illustrates an embodiment of a system of custom-made footwear 100. In the illustrated embodiment, the system of custom-made footwear 100 includes a data collection system 110, a data processing system 120, a production system 130, and a data collection 140.
The data collection system 110 collects data about a particular user, such as information about the user's foot (s). The data collection system 110 may include a component for collecting static data 112 and a component for collecting dynamic data 114.
The component for collecting static data 112 collects user-specific static data. As described above, the static data collection component 112 may include a means for collecting basic data relating to the user, such as basic anatomical data and subjective data (e.g. user preferences). For example, the static data collection component 112 may include a user interface for inputting manual measurements of user characteristics or attributes (e.g., a shoe size).
The component for collecting static data 112 may also include: image sensors, such as video cameras or cameras, scanners, such as optical and scanners using lasers, medical imaging systems such as X-ray, MRI or CAT scanners, and other sensor systems, such as pressure sensitive tires. The static data collection component 112 may include, for example, a camera used to photograph a body part of a user, for example, a user's foot. The digital photograph is therefore a two-dimensional user-specific static data that can be used in the course of the design of the custom-made footwear.
The static data collection component 112 may also include a pressure sensitive tape which, when a user steps on it, generates two-dimensional pressure data associated with the user's foot.
The dynamic data collecting component 114 collects user-specific dynamic data. As described above, the dynamic data collecting component 114 may include pressure sensitive bands, portable sensors, motion detection sensors, or image recording systems. The said devices can generate two-dimensional or three-dimensional user-specific dynamic data.
A user can, for example, step off or walk the length of a large pressure-sensitive belt and this can then record dynamic data each time a foot lands, rotates and then releases itself from the path. Similarly, a user can jump up and down on a pressure sensitive belt. In a number of embodiments, moving or still images can be collected together with data from other sensors (e.g. data from a pressure-sensitive belt) in such a way that the data from the sensors can be added to the actual physical movements of the user's foot for further analysis.
In a number of embodiments, a single sensor, e.g., a pressure-sensitive tape, can be used to collect user-specific static data (when it is on a path, for example) and user-specific dynamic data (when it is stepping on the path, walking, jumping, etc.). ). Similarly, an image sensor such as a camera can be used to collect user-specific static data (e.g., still images) and user-specific dynamic data (e.g., high-resolution video or still images).
In some embodiments, the data collection system 110 is portable and independent of other elements of the tailor-made footwear system 100, while in other embodiments it may be an integral part of it. The data collection system 110 may include sensors (e.g., pressure sensitive tapes and cameras) as well as the processing devices that support these sensors (e.g., mobile equipment, computers, servers, and the like).
The data collection system 110 may include local data collections (not shown in the drawing) and / or remote data collection connections, for example data collection 140. The data collected by the data collection system 110 may be stored in local data collections or in data collections on distance (or both) after being observed, measured, determined, entered or created in any other way.
The data collection system 110 may be in data communication with other elements of the customized footwear 100 system through, for example, wired or wireless data connections. For example, in embodiments where the data collection system 110 is portable and independent of other elements of the tailor-made footwear system 100, the data collection system 110 can connect these components and share data through a connection such as the internet. In other embodiments, the connection may instead be ad hoc between different components.
The data processing system 120 is in data communication with the data collection system 110. The data processing system 120 can receive static and / or dynamic data collected by the data collection system 110 and use that data in the design of custom-made footwear.
The component design component 122 may, for example, take user-specific static data, such as image data, to build a two-dimensional or three-dimensional model of a body part of a user, for example, a foot. The component design model 122 may further take other user-specific static data, such as pressure-sensitive data, and lay it on or otherwise combine it with the two-dimensional or three-dimensional model. For example, a three-dimensional model of a body part, for example, a foot, could be further adjusted using static pressure data in such a way that it is fashionable! displays static pressure on different parts of the foot model. These differences can be depicted by way of example by means of a color scale such as in a "heat map". More specifically, the data can be transferred to the two-dimensional or three-dimensional model, or projected onto a two-dimensional projection of the three-dimensional model, such as in the form of a two-dimensional pressure distribution on the bottom of a user's foot.
The component for designing models 122 may further take user-specific dynamic data, such as pressure-sensitive data, and lay it on or otherwise combine it with the two-dimensional or three-dimensional model. For example, forces acting on a three-dimensional model of a body part of a user, for example, a foot, can be imaged using said heat map, or by means of, for example, vectors representing the direction and magnitude of forces that act on the model of the user's foot. Numerous means are known to those skilled in the art to combine the different types of user-specific data.
The component for designing models 122 can furthermore take statistical data, for example population data, and combine this with other user-specific data. By way of example, if only external characteristics are known of a body part of the user (e.g. by image data), statistical data, e.g. a statistical shape model, can be used to supplement two-dimensional or three-dimensional models of a body part of the user. For example, if external characteristics are known, the predicted bone structure of a user's foot could be built into a model by means of statistical shape models. Similarly, if only internal characteristics are known of a user's body part (e.g., by X-ray data), the predicted external structure of a user's foot can be built into a model by means of statistical shape models.
The model design component 122 can access statistical data from, for example, the data set 140. In addition, the model design component 122 or the footwear design component 124 can generate statistical data based on store the user-specific data received, and the generated statistical data locally or in the data set 140.
Classifications regarding certain attributes of a user's body part (e.g., a foot) can be made in the course of the process of receiving user-specific data and designing a model of the user's body part. By way of example, static or dynamic measurements of a user's foot on a pressure-sensitive belt can be used to generate an "arc index." Furthermore, the determined arc index can be used for the purpose of classifying the user's foot into a plurality of standard anatomical "arc types". "
By way of example, measurements of the contact surfaces of the forefoot, midfoot and heel (hereinafter A, B and C) can be used to determine an "arc index" (AI) in accordance with the following equation: B / (A + B + C) = AI. Based on this comparison, a user's arc type can be classified into categories, for example, the following example categories:
The component for designing models 122 may include body part templates, for example, two-dimensional or three-dimensional models intended to be used as a starting point for a user-specific body part model. In some cases, the templates can be based on statistical shape models, while in others, the templates can be designed individually. Templates can be useful if the user-specific data is scarce or inaccurate.
The footwear design component 124 can use received data, such as user-specific static and dynamic data, model data, classification data and the like to design a customized footwear model.
In a number of cases, the component for designing footwear 124 may design a custom-made footwear portion, such as an insole, midsole, or outer sole. Furthermore, the design of the tailor-made footwear part may contain one or more corrective aspects, for example microstructures, with a view to influencing the mechanical behavior of the footwear on the basis of the design footwear model. In this way, custom-made footwear can be designed with a view to correcting or improving a biomechanical function of the user's foot, for example. Additionally, the footwear design component 124 may determine a suitable material or represent a range of materials to be used in the production of the footwear.
For example, the footwear design component 124 can be used to design a custom-made insole that contains microstructures that make certain parts of the insole stiffer while promoting flexibility in specified directions in other parts of the insole. The tailor-made insole can then be made from a specific material that is selected because of its physical properties (e.g. strength, elasticity, weight etc.).
In some embodiments, the footwear designing component 124 may perform tests on a design footwear model to check and validate the design. The footwear design component 124 may, for example, perform a Fixed Element Analysis (FEA) or the like to control the desired effects of various corrective aspects and to validate the design model as a whole. In this way, design footwear models can be thoroughly tested in a virtual environment before the actual footwear is produced.
The footwear design component 124 may include footwear templates, for example two-dimensional or three-dimensional models, intended to be used as a starting point for design footwear models. In some cases, the templates can be based on statistical shape models, while in others, the templates can be designed individually.
In a number of embodiments, the footwear design component 124 includes programming configured with a view to automatically creating a footwear design based on one or more models of a user's foot, for example those created by the component for designing models 122. In such embodiments, the component for designing footwear 124 can process a model of a body part of the user, for example a foot, and determine one or more corrections that should be made by means of a design of customized footwear for the purpose of, for example, treating a condition, preventing a condition, or improving performance. The programming used for the automatic creation of footwear designs can rely on user-specific data and on statistical data such as population data, in order to determine a suitable design of custom-made footwear. In a number of embodiments, the footwear design component 124 may offer an operator the option of selecting various footwear parts to be designed, for example, bodies, insoles, midsoles and outer soles. In other embodiments, the footwear designing component 124 may automatically decide based on the programming.
In some embodiments, the component for designing footwear 124 is semi-automatic and not fully-automatic. For example, in such embodiments, the footwear designing component 124 can automatically select a template design and apply certain corrective aspects to it, but can stop at predetermined points to wait for an input on an design operator.
In other embodiments, the footwear designing component 124 can be used manually by a designer for the purpose of creating customized footwear designs. In such embodiments, a designer may have the option of choosing from a variety of options for designing the footwear, such as which parts to design, as well as options for the characteristics of these parts, including the features to be used in these parts corrective aspects. Furthermore, a footwear part, for example an insole, can be further subdivided into one or more zones for the purpose of designing the footwear model. Each zone can exhibit individual characteristics designed to correct, improve or otherwise alter the biomechanical properties of the foot.
The component for designing footwear 124 may be, for example, CAD or CAM software. In a number of embodiments, the footwear design component 124 may be specialized CAD or CAM software configured for the purpose of designing custom-made footwear parts, for example, bodies, insoles, midsoles, or outsoles. In a number of embodiments, the component designing component 122 and the footwear designing component 124 are integral, for example, when a single software component can perform both functions. In other cases, each component can form a separate module.
In a number of embodiments, the data processing system 120 may include a model of a data processing component (not shown in the drawing), which may be configured for performing a method of processing model data including the processing of preliminary data, indicatively for at least one characteristic to be used in defining a surface of the object to be produced by an additive manufacturing technique. In other embodiments, the method may also include: generating surface data representative of a surface of at least a portion of the object to be produced by an additive manufacturing technique based on the processed preliminary data, and generating of disk data relating to at least one disk of the object to be produced by an additive manufacturing technique. These and other embodiments are described in British Patent Application No. GB1314421.7 under the title "Data Processing", which is incorporated herein by reference in its entirety.
Preliminary surface data may be indicative of at least one feature to be used in defining a surface of an object to be produced by an additive manufacturing technique. In particular, the surface to be defined has a surface zone and a three-dimensional spatial configuration. Preliminary surface data can thus be data defining at least one precursor to be used in defining the surface and not directly representing a surface of an object. However, the preliminary surface data can be used to calculate a surface area of the object in whole or in part. As such, preliminary surface data can be considered as indirectly defining a surface of at least a portion of an object to be produced by an additive manufacturing technique. Note that a line that only defines a perimeter of the surface does not define a surface of an object if the perimeter does not define a surface with a surface area.
The use of preliminary surface data can reduce the size of the data files representative of an object to be produced by an additive manufacturing technique as compared to other data formats such as STL or AMF or other formats known in the art. Reducing the size of a data file representative of an object to be produced by an additive manufacturing technique can lead to an increased transfer speed and efficiency in a data network (e.g., between the data processing system 120 and the production system 130). Furthermore, the hardware requirements of a computer and the requirements of the network such as the available bandwidth can be favorably reduced due to the reduced size of the database.
Finally, reducing the size of the data file can improve the speed and efficiency of processing the data file (compared to known data formats such as the STL and AMF formats) to create disk data as an instruction for an example. establishment of additive manufacturing, for example the establishment of additive manufacturing 134.
In particular, the use of preliminary surface data may also reduce the size of the data files representative of an object to be produced by an additive manufacturing technique, if this object contains complex structures such as porous structures, mesh structures, lattice structures, and structures with complex surface details. In known data formats such as STL and AMF, the configuration of a surface of an object to be produced by an additive manufacturing technique is directly represented by data representative of a triangular lattice, i.e., a plurality of adjacent mosaic tiles triangles. Note that the surface of an object is a surface zone that defines a surface of any part of the object. The surface can thus define external surfaces of an object as well as internal surfaces of an object that, for example, define a cavity or a porous structure within the object. To define more complex surfaces, for example the surface of a porous structure, smaller triangles are used in known methods to provide the increased granularity needed to describe the complex surface. The use of smaller triangles to define more complex surfaces leads to a larger number of triangles that are needed to define any surface of the object. In known data formats such as STL and AMF, each triangle of the triangular grid is encoded by coordinate data for each of the three corners of the triangle. When determining a large number of small triangles to describe a complex surface, the size of the resulting file may therefore become too large to be sent and / or processed in a practical manner.
In some embodiments, the data processing system 120 is portable and independent of other elements of the tailor-made footwear system 100, while in other embodiments it may be an integral part of it. The data processing system 120 may, for example, be a portable computer system such as a laptop. In other embodiments, the data processing system 120 may be remote from the other components of the tailor-made footwear system 100. For example, the data processing system 120 may be a remote server receiving data via data links and that processes data remotely.
The data processing system 120 may include local data sets (not in the drawing) and / or connections to remote data sets, for example, data set 140. The output of the component design model 122 (e.g., a user-specific model) part of a body part) and component for designing footwear 124 (e.g. a customized footwear model) can be stored in the data set 140.
The data processing system 120 may be in data communication with other elements of the custom-made footwear system 100 through, for example, wired or wireless data connections. For example, in embodiments where the data processing system 120 is portable and independent of other elements of the tailor-made footwear system 100, the data processing system 120 may connect these components and share data through a connection such as the internet. In other embodiments, the connection may instead be ad hoc between different components.
The production system 130 may comprise a controller 132 and an additive manufacturing 134 device. The production system 130 may receive data from a data processing system 120 for the production of custom-made footwear or custom-made footwear parts, for example insoles, midsoles or outsoles. The production system 130 may receive data on the design of the customized footwear in the form of STL or PLY formatted files that can be interpreted by the controller 132 for control purposes, for example, from the data processing system 120 of the device of additive manufacturing 134. The production system 130 will be described in more detail in what follows, with reference to Figure 7.
Note that the lines of data communication shown between the data collection system 110, the data processing system 120, the production system 130, and the data collection 140 in Figure 1 are intended to be illustrative only. The paths of data communication between the various components of the system of custom-made footwear 100 can be direct or indirect, can traverse one or more networks, can contain intervening devices, can be wired or wireless, can use different protocols, can use different media, etc. Moreover, the paths of the data communication can be one-way or two-way, so that the data can be shared between different elements.
In a number of embodiments, the components of the system of tailor-made footwear 100 as illustrated in Figure 1 may be integrated into a single system. In such embodiments, a user may have the ability to be scanned (e.g., using image sensors) and tested (e.g., using pressure-sensitive bands) and then receive custom-made footwear or footwear parts such as a body, an insole, a midsole or an outside mess, all in the same place. In such embodiments, an operator may be present to participate in or at least validate the design of the customized footwear. In other embodiments, however, the entire process can be automated. In a number of embodiments, the entire system of customized footwear 100 may be, for example, a kiosk or the like in a shoe store, sports store, and the like.
In other embodiments, the components of the tailor-made footwear system 100 may be separate. The data collection system 110 may, for example, be separate from the data processing system 120 and the production system 130 (although the latter two systems may be integral or may be in the same location). By way of example, a kiosk or the like may include a data collection system with various sensors, for example, image sensors and pressure sensitive bands, which are in data communication with a data processing system 120 and a production system 130 at a different location. Note that if these different components can be physically separated in a number of embodiments, they can still be together at a specific location such as a footwear store, so that the user can be scanned at the same location and provided with custom-made footwear.
In still other embodiments, the data collection system 110 and the production system 130 may be in the same location and the data processing system 120 in a different location. Because of the complex processing performed by the data processing system 120, it may be desirable to separately locate the data processing system 120 from the data collection system 110 and the production system 130, for example in a remote server. For example, a footwear store may provide the data collection system 110 and the production system 130 at the same location, while the data processing system (and possibly its operator) are at a completely different location. In this way, a seller of tailor-made footwear can limit the costs and space associated with each of the components and possess only those components of the system of tailor-made footwear 100 that are most comfortable for the users. Such embodiments would also allow suppliers of custom-made footwear systems to use different distribution and sales models. For example, a supplier of custom-made footwear systems could sell certain components of the system, for example the data collection system, and offer a model of registration for other components, for example the data processing system. Finally, the system of tailor-made footwear 100 can be just as integral or modular as necessary for a specific end user of the system.
Figure 2 illustrates a method 200 for the design of custom-made footwear, such as a body, an insole, a midsole, or an outer lining.
The method 200 starts at step 202, where user-specific data is received. As described above, user-specific data may contain static and dynamic user-specific data. The user-specific data may be received from, for example, a data collection system such as the data collection system 110 as described with reference to Figure 1.
The method then proceeds to step 204, where statistical data is received. As described above, for example, statistical data may include statistical shape models of various anatomical features based on population data. However, other statistical data is also possible. By way of example, elemental measurements based on a known shoe size of a user can be used.
The method 200 then proceeds to step 206, where a user model is generated. As described above, the user model can be a two-dimensional or three-dimensional model of a body part of a user, for example a foot of a user. The user model may be based on some or all of the user-specific data received in step 202 and the statistical data received in step 204. In a number of embodiments, such as when little or no user-specific dynamic data was received, the user model can be generated primarily on the basis of statistical data or on a template, or both.
The user model 206 optionally generated in step 206 may contain numerous additional elements in addition to mere two-dimensional or three-dimensional shape data. The user model can, for example, be supplemented with static or dynamic data, for example pressure data. This data can improve the model with a view to designing suitable custom-made footwear.
The method 200 then proceeds to step 208, where user-specific points or problems are identified based on the user model.
In a number of embodiments, user-specific points are determined by comparing the user model with, for example, an ideal model of a body part, for example, a foot. The user model can be compared with shape models and with performance models (for example models of ideal pressure distribution). In a number of embodiments, the user model contains dynamic data that is compared to "ideal" dynamic data (e.g., models of the foot contacts). In other embodiments, the user model can be compared to templates or statistical shape models to identify potential problems. Problems such as pronation, supination, bunion, misalignment, flat feet, arc problems, performance problems and others can be identified based on the user model.
In other embodiments, user-specific points can be identified based on a manual check of the user model by, for example, a trained technician, an orthopedic doctor, etc. In such a scenario, the aspects can be identified manually but the corrective aspects can be generated automatically .
The method 200 then proceeds to step 210, where corrective aspects are determined around one or more of the user-specific points identified in step 208. As described above, many types of corrective structures can be used to design corrective footwear, including microstructures.
For example, suitable microstructures can be determined to prevent unwanted movement in selected directions while allowing free movement in other directions. Similarly, thickness adjustments in different zones of a footwear section can be determined to provide a more uniform support. Other corrective aspects can also be determined, as described above.
The method 200 then proceeds to step 212, where a custom-made footwear model is generated. The tailor-made footwear model may, for example, contain a footwear part, such as a body, an inlay sole, a midsole, or an outer sole.
In a number of embodiments, the customized footwear model is initially a footwear template, which is only partially tailored based on basic user-specific data. The made-to-measure footwear model can start, for example, in the form of a template of a body of a footwear, an insole, a midsole, or an outer sole for a user with a specific shoe size. The template can then be further customized to incorporate, by way of example, one or more of the correcting structures determined in step 210.
In some embodiments, an initial template can be based on certain classifications or categorizations of anatomical types, for example, the different types of foot arches as described above. Such classifications or categorizations regarding a user's body part can improve the speed and accuracy of an initial model based on a template.
In other embodiments, the customized footwear model is not generated from a template, but is generated almost exclusively on the basis of user-specific data. This may be the case when complete user-specific data exists for a specific user.
In a number of embodiments, the customized footwear model is automatically generated by suitable software. In other embodiments, the customized footwear model can be generated semi-automatically or fully manually.
The method 200 then proceeds to the final step 214, where the tailor-made footwear, such as a body, an insole, a midsole, or an outer sole, is produced.
In a number of embodiments, custom-made footwear is produced by means of additive manufacturing techniques, as described above, or by other techniques known in the art.
As described above, custom-made footwear can address user-specific problems and contribute to the prevention of injuries and the development of foot conditions, or even to the improvement of biomechanical performance (for athletes, for example).
Figure 3A illustrates a graphical user interface of an example data collection system, such as the data collection system 110 of Figure 1. In Figure 1, dynamic user-specific footprint data 302 is displayed on a graphical user interface. In these embodiments, the pressure data 302 indicates the pressure applied to a pressure sensitive tape at a specific time. In this embodiment, the print data is color-coded, so that certain colors indicate a higher print than other colors.
Figure 3A also shows a particular vector 304 indicating the center point and direction of the average pressure exerted by the user's foot on the pressure sensitive belt at a specific time.
Figure 3A also shows dynamic pressure data 306 as a function of time. This data can be useful to identify where in the dynamic movement of the user the pressure is maximized, so that corrective structures can be designed to reduce the maximum pressure points. The particular vector may be useful to determine the alignment of the step and the foot contact of a user, or to determine the equilibrium characteristics of the user's step.
Figure 3A also shows average dynamic data 308. The average dynamic data illustrates the average pressure of the user's foot on the pressure-sensitive belt after a plurality of steps. In particular, a "hot spot" (i.e., a relatively higher pressure zone) is determined by the study of the average dynamic data 308. The hot spot 310 can be identified as a user-specific problem as described above with respect to step 208 in figure 2.
The user-specific data illustrated in Figure 3A can be sent to, for example, a data processing system such as the data processing system 120 as illustrated in Figure 1, and used by that system to generate or supplement a user model.
Figure 3B shows a graphical user interface of an example of a footwear design component, such as the footwear designing component 124 of the data processing system 120 as illustrated in Figure 1. More specifically, Figure 3B illustrates an example of a part 312 of a footwear (here an insole) containing a plurality of zones (e.g. zone 314). The part 312 of a footwear contains corrective structures, such as thickened parts (as indicated by the inclination angle 316).
Note that Figure 3B is only a single embodiment of a component of a footwear design. Different embodiments with more complete design options are possible.
Figure 4 illustrates tailor-made footwear (a footwear) 400, comprising a body 402 and an integral sole structure comprising an insole 4406, a midsole 404 and an outer sole (i.e., a tread) (not in the drawing). In this embodiment, the entire shoe 400 was designed and printed three-dimensionally using the methods described above.
The body 402 of shoe 400 was printed three-dimensionally with a view to creating a complex yet light and strong design. In particular, the various properties of the body 402 are unique to the anatomical features of a user and his biomechanics. Advantageously, the body 402 provides improved support and comfort while at the same time being lighter and less substantial than conventional footwear designs that are not made to the size of a user.
The shoe 400 also includes a three-dimensional printed integral sole structure comprising an insole 406, a midsole 404 and an outer sole each of which, for example, contains microstructures that give these individual layers different mechanical properties. Note that even though the structure of the insole is integral, the different parts of the structure of the insole (i.e., insole, midsole, and outer sole) may still be designed separately. An advantage of additive manufacturing is the ability to independently design parts of footwear and then combine them into a single piece of work. Consequently, a much better tailor-made sole structure can be made by means of additive manufacturing techniques as compared to soles that are created by traditional production techniques. Since traditional production techniques are generally limited to homogeneous layers of materials, they cannot reach the level of customization of shoe 400.
Note that, while the embodiment of Figure 4 is that of a footwear, the methods and devices described in this text can be applied in the same way, and thus also offer similar advantages, for other types of footwear, including, for example, boots, sandals, slippers, sneakers, flats, pumps, heels, and other types known in the art.
Figure 5A illustrates tailor-made footwear (a shoe) 500, comprising a body 502 and a midsole 504, as well as corrective aspects 506, 608 and 510. The shoe 500 may be designed and produced by a tailor-made footwear system as illustrated and described with reference to Figure 1.
The shoe 500 includes a body 502 containing two different zones with corrective aspects 506 and 510. In this embodiment, the corrective aspect 506 includes three-dimensional cellular microstructures intended to reinforce the heel and ankle portions of the body 502 of the shoe 500 while the low weight and flexibility are retained. Consequently, the characteristics of the cellular microstructures in the corrective aspect 506 lead to high strength and a sufficient flexibility but a relatively low density (i.e. material per unit volume), so that the weight remains low compared to conventional materials used for footwear. are used. Furthermore, in this embodiment, the microstructures were selected based on user data that seemed to demonstrate an imbalance of squa step and supination (i.e., the foot rolling out).
The corrective aspect 508 is in the center zone! 504 of the shoe 500. The corrective aspect 508 contains cellular microstructures that are different from those of the corrective aspect 506. More specifically, the cellular microstructures in the corrective aspect 508 are designed for strength and durability, and for weight easily supported by the user while still retaining sufficient visco-elastic properties to absorb the shocks. In view of this, the microstructures are arranged in a different pattern than that of the corrective aspect 506 and were designed to primarily provide support and resilience toward the foot contacts (i.e., up and down). In this embodiment, the microstructures were selected based on user data demonstrating that the user's foot contacts first occur with the heel.
The corrective aspect 510 is located in the body 502 of the shoe 500. The corrective aspect 510 contains three-dimensional microstructures that are designed to be flexible enough to adapt to the top of the foot but exhibit sufficient limited stretch properties to the top of to provide strong support in the course of dynamic activities. Furthermore, the three-dimensional microstructures in the corrective aspect 510 exhibit a relatively low density in view of reducing the weight and promoting breathing of the user's foot in the footwear.
The shoe 500 was printed three-dimensionally with a production system 130 as illustrated and described with reference to Figures 1 and 7. By three-dimensional printing of the entire shoe 500, the entire shoe 500 was adapted to the specific foot of the user. Additionally, the shoe 500 includes a wide range of corrective aspects that have been specifically designed with a view to improving the biomechanical action of the user's foot in use. The corrective aspects could also be incorporated layer by layer in the shoe 500. The shoe 500 could also be built with less total material consumption due to the flexibility of the additive manufacturing system.
Figure 5B illustrates certain aspects of a microstructure, for example a microstructure that can be found in a corrective aspect. A cellular structure, e.g., cell 508, may contain a plurality of edges that are connected to a node, e.g., node 510. The node 510 provides a physical connection between the edges, and resists a change in their mutual angles. When cell 508 is elongated (i.e., substantially ellipsoidal), the mechanical properties are different based on whether a load is applied parallel to the long axis of the cell, or transversely to the long axis. Thus, the cell 508 is less likely to be compressed and to jump back rapidly at a load exerted parallel to the long axis, while it will compress more rapidly and return more slowly to its previous state at a load exerted transversely of the long axis.
Cell 512 contains a horizontal gain that amplifies cell 512 (i.e., counteracts the distortion of cell 512) compared to cell 508. Such a microstructure gain may be beneficial for zones, such as a midsole, where the microstructures have a relatively larger supporting weight and carrying stronger transient forces than other parts of the footwear. Note that the increased strength and reduced elasticity of cell 512 due to the horizontal gain primarily has an effect on cell 512 in the direction of the gain (i.e. from side to side) and not in the transverse direction on the reinforcement (ie up and down). In this way microstructures can be designed with a view to providing specific targeted properties to the various parts of the footwear in which they are incorporated.
Figures 6A and 6B illustrate a portion 600 of custom-made footwear from different angles (substantially above and below). The part 600 of the tailor-made footwear is based on user-specific data, as described above and with regard to the data collection system 110 of Figure 1. The design of the part 600 of the tailor-made footwear was created by means of a system for data processing such as that illustrated and described with reference to Figure 1. Finally, the part 600 of the customized footwear was produced with an additive manufacturing technique as described above, with an additive manufacturing system as illustrated and described with reference to figures 1 and 7.
The part 600 of the tailor-made footwear contains corrective aspects. For example, the overall thickness of part 600 of the tailor-made footwear was deliberately varied to exert an influence on the weight distribution of a user and to promote proper foot movement and provide more comfort. The portion of the customized footwear 600 also includes ribs 602 (as illustrated in Figure 6A) that promote bending in a desired direction and counteract bending in other directions. Finally, the part of the tailor-made footwear also contains corrective microstructures (as illustrated in Figure 6B).
As illustrated in Figure 6B, the microstructures 604 are complex three-dimensional cellular structures created layer by layer by, for example, an additive manufacturing technique as described above. The axes of the microstructures illustrated in Figure 6B are oriented with a view to influencing the torsional resistance of the part 600 of the custom made footwear.
In some embodiments, the shafts of the microstructures are not necessarily parallel in each area or zone of the part of the tailor-made footwear. By way of example, in some embodiments, the axes of the microstructures may diverge from a common point, for example, a point in the heel region.
Figure 7 illustrates an example of an additive manufacturing 700 device that can be configured with a view to performing additive manufacturing techniques such as SLA, SLS and SLM and other techniques known in the art to produce customized footwear, e.g. customized footwear parts illustrated in Figures 6A and 6B.
The device of additive manufacturing 700 includes a controller 710 which is in data communication with a transmitter 720, a scanner 730 and a platform 740. Note that a similar device of additive manufacturing for performing FDM can replace the transmitter 720 and the scanner 730. by an extrusion head and associated mechanical controls.
The controller 710 may, for example, be a computer system with software for operating the device of additive manufacturing 700. In other embodiments, the controller 710 may be in the form of a universal processor or a digital signal processor signal processor, DSP), an application-specific integrated circuit (application-specific integrated circuit, ASIC), a field-programmable gate array (field programmable gate array, FPGA) or another programmable logic unit, a separate port or transistor, separate hardware components, or any combination thereof to perform the functions known in the art.
As before, the lines of data communication displayed between the controller 710 and the transmitter 720, the scanner 730, and the platform 740 are intended to be illustrative only.
The controller 710 can control the transmitter 720. The controller 710 may, for example, send data signals to transmitter 720 for the purpose of switching the transmitter on and off. In addition, the controller 710 can control the output power of the transmitter 720. In a number of embodiments, the controller 710 can control multiple transmitters 720 (not in the drawing) in the same device of additive manufacturing 700. In a number of embodiments, the transmitter 720 can also send data back to the controller 710. For example, the transmitter 720 can send operational parameters such as the output power, the power consumption, the temperature, and other operational parameters known in the art. The operational parameters of the transmitter 720 can be used by the controller 710 to further control or optimize the processing of object 750.
The controller 710 can also control the scanner 730. The controller 710 may, for example, determine the selection, handling, rotation, clamping or other uses of optical elements 734. For example, the controller 710 may cause a focusing lens to move in view of influencing the size of a resulting beam 736 or a resulting beam spot 738. Furthermore, the controller 710 may cause a mirror or similar optical element to resulting beam 736 redirects in different directions and at different locations of object 750. Yet another example is that the controller 710 may cause a shutter or similar optical element to hide the resulting beam 736 even when the transmitter 720 is active .
In a number of embodiments, the controller 710 may retrieve data from the scanner 730. For example, the scanner 730 may transmit operational parameters such as output power, power consumption, temperature, beam size, beam power, beam direction, beam spot direction, position of the optical elements, condition of the optical elements, and other operational parameters known in the art. The operational parameters of the transmitter 720 can be used by the controller 710 to further control or optimize the processing of object 750. In a number of embodiments, the controller 710 may form part of the scanner 730.
The controller 710 can also control the platform 740. For example, the controller 710 may cause the platform 740 to move in one or more dimensions (e.g., up and down, or from side to side). The controller 710 can receive operational data from the platform 740, such as the position, temperature, weight, proximity, and other operational parameters known in the art. The controller 710 may cause the platform 740 to move in steps of one layer of the object 750 at a time such that the scanner can process a layer of material to add it to the object 750. The layers of the object 750 can be defined in three-dimensional design drawings (for example, 3D CAD), or in one or more two-dimensional sectional drawings (for example, 2D CAD).
In a number of embodiments, the controller 710 can store or access data about the design of the object in some other way, for example, 3D CAD drawings of an object to be produced by means of an optical device of additive manufacturing 700. The controller 710 may, for example, form part of a computer system that also contains software and hardware for object design, for example CAD software. In this way, the controller 710 can access data about the design of the object for controlling the transmitter 720, the scanner 730 and the platform 740 and to produce the object 750. In other embodiments, the controller 710 may be connected by means of a communication path to a data storage location, a data file and the like of design data, for example the data file 760 in Figure 7.
In a number of embodiments, the controller 710 may receive data on the design of footwear from, for example, the data processing system 120 of Figure 1. In this way, the controller 710 can control production by means of an additive manufacturing technique. manage custom-made footwear, including custom-made footwear parts such as insoles, midsoles and outsoles.
The transmitter 720 may, for example, be a laser transmitter such as a diode laser, a pulsed laser, a fiber laser, or other laser types known in the art. In a number of embodiments, the transmitter 720 may be a UV laser, a carbon dioxide laser, or a ytterbium laser. The transmitter 720 may be of a different type of beam-emitting laser, as is known in the art.
The transmitter 720 emits a beam, for example laser beam 722, which is then processed by the scanner 730. Note that, although not shown in Figure 7, optical elements such as mirrors, lenses, filters, etc. can be placed between the transmitter 720 and the scanner 730.
In a number of embodiments, the transmitter 720 may form part of the scanner 730.
The scanner 730 can contain optical elements 734. Optical elements can be, for example: lenses, mirrors, filters, splitters, prisms, diffusers, windows, displacers, and other optical elements known in the art. The optical elements 734 can be fixed or movable, based on data received by the scanner 730 or the controller 710.
The scanner 730 may also contain sensors (not shown in the drawing) which, in the course of the operation of the scanner 730, gaze at various operational parameters. Generally speaking, the sensors can provide feedback data to the scanner 730 and / or the controller 710 with a view to improving the calibration and production performance of the optical device of additive manufacturing 700.
The scanner 730 may include, for example, position sensors, heat sensors, distance sensors and the like. Additionally, the scanner 730 can include one or more image sensors. The image sensors can be used to provide visual feedback to the operator of the optical device of additive manufacturing 700. The image sensors can also be used, for example, to analyze the size, focus and position of the beam spot that falls on the object being produced, with a view to calibration and accurate follow-up. Furthermore, the image sensor may be heat sensitive (e.g., a thermal image sensor) and be used to determine the condition of the underlying material (e.g., resin) when it is being processed. For example, a thermal image sensor can measure the local warming around the beam spot and / or the level of curing of the material being processed.
The platform 740 acts as a movable base for the production of object 750, which can be custom-made footwear. As described above, the platform 740 can move in one or more directions and be controlled by a controller, for example, controller 710. The platform 740 can be controlled by controller 710 and one layer of the cross-section of the object 750 at a time moved in the course of the production of the object 750.
The platform 740 may include sensors that record operational data and transmit that data to the controller 710 or to other parts of the optical device of additive manufacturing 700.
The platform 740 may be contained in a receptacle (not shown in the drawing) containing production materials (e.g., a photosensitive resin) that are processed by an incident beam spot directed by the scanner 730. The scanner 730 may, for example, direct a beam over a layer photosensitive resin, which causes the resin to cure and forms a permanent layer of the object 750.
The platform 740 can be made of any suitable material with adequate strength and resilience to serve as a basis for the production of an object such as the object 750.
In addition to a container around the platform 740, the device of additive manufacturing 700 can also contain an element distributing the production material. For example, an element can distribute a new layer of production material after each resp. layer of the object 750 has been completed by the operation of the scanner 730.
The object 750 is formed by the device of additive manufacturing 700 by various methods, for example SLA, SLS, SLM and other methods known in the art.
Figure 8 illustrates an example of a computer device 800 such as can be used in combination with the data collection system 110, the data processing system 120, and / or the production system 130 of Figure 1.
The computer device 800 includes a processor 810. The processor 810 is in data communication with various computer components. These components may include a memory 820 as well as an input device 830 and an output device 840. In some embodiments, the processor may also communicate with a network interface card 860. Although described as a separate component, it should be understood that the functional blocks described are with regard to the computer device 800, there must be no different structural elements. For example, the processor 810 and the network interface card 860 can be included in a single chip or a single board.
The processor 810 can be a universal processor or a digital signal processor (digital signal processor, DSP), an application-specific integrated circuit (application-specific integrated circuit, ASIC), a field-programmable gate array (field programmable gate array, FPGA) or another programmable logic unit, a separate port or transistor, separate hardware components, or any combination thereof to perform the functions described in this text. A processor can also be implemented as a combination of computer equipment, for example a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in combination with a DSP core, or any other such configuration.
The processor 810 can be coupled, via one or more data buses, to read information from, or write to, the memory 820. The processor can additionally, or as another possibility, contain memory, for example processor registers. The memory 820 may contain processor cache, including a multi-level hierarchical cache in which different levels have different options and different access speeds. This memory 820 may further comprise a random access memory (write access memory, RAM), as well as other devices with a volatile memory or devices with a non-volatile memory. The data storage can consist of hard disks, optical disks such as compact dises (CDs) or digital video dises (DVDs), flash memory, diskettes, magnetic tape, Zip drives, USB drives, and other components known in the art.
The processor 810 can also be coupled to an input device 830 and an output device 840, respectively. obtain input from, and provide output to, a user of the computer device 800. Suitable input devices include, but are not limited to, a keyboard, a rollerball, buttons, keys, switches, pointing devices, a mouse, a joystick, a remote control device, an infrared detector, a voice recognition system, a barcode reader, a scanner, a video camera (possibly coupled with image processing software to detect, for example, hand or face movements), a motion detector, a microphone (possibly linked to sound processing software, to detect, for example, voice commands) , or any other device suitable for transferring data from a user to a computer device. The input device may also take the form of a touchscreen associated with the display, in which case a user responds to information displayed on the display by touching the screen. The user can enter information in the form of text by means of an input device such as a keyboard or the touchscreen. Suitable output devices include, but are not limited to, visual output devices, including screens and printers, audio output devices, including speakers, headphones, earphones and alarms, additive manufacturing devices, and haptic output devices.
The processor 810 can further be coupled to a network interface card 860. The network interface card 860 prepares data generated by the processor 810 for transmission over a network in accordance with one or more data transmission protocols. The network interface card 860 can also be configured for decoding data received by the network. In a number of embodiments, the network interface card 860 may include a transmitter, a receiver, or both a transmitter and a receiver. Based on the specific embodiment, the transmitter and the receiver may consist of a single integrated component or may be two separate components. The network interface card 860 may be in the form of a universal processor or a DSP, an ASIC, an FPGA, or other programmable logic unit, a separate port or transistor, separate hardware components, or any combination thereof to perform the functions described in this text.
The invention described in this text can be implemented in the form of a method, a device, a produced article, using standard techniques of programming or engineering to produce software, firmware, hardware or any combination thereof. The term "produced article" as used herein refers to code or logic implemented in hardware or permanent computer readable media such as optical disks, and volatile or non-volatile memory devices or temporary computer readable media such as signals, carriers, etc. Such hardware may include, but is not limited to, FPGAs, ASICs, complex programmable logic devices (complex programmable logic devices, CPLDs), programmable logic arrays (programmable logic arrays, PLAs), microprocessors, or other similar processing devices .
Those skilled in the art will appreciate that numerous variations and / or modifications to the invention can be made without departing from the spirit or scope of the invention as extensively described. The embodiments described above must therefore always be regarded as illustrative and non-limiting. in the drawings:
FIG. 1
FIG. 2
FIG. 7
FIG. 8

权利要求:
Claims (20)
[1]
CONCLUSIONS
A method for creating a piece of footwear based on a user model, the method comprising: receiving user data associated with a user; generating a user model based on the received user data; determining one or more corrective aspects based on the user model, generating a customized footwear model that contains a certain corrective aspect; and creating a piece of footwear based on the customized footwear model.
[2]
The method of claim 1, wherein the piece of footwear is created by means of an additive manufacturing technique.
[3]
The method of claim 1, wherein the user data includes one or more of: foot pressure data, step data, body data, or image data.
[4]
The method of claim 1, wherein determining one or more corrective aspects is additionally based on statistical data.
[5]
The method of claim 4, wherein the statistical data includes a statistical form model.
[6]
The method of claim 2, wherein the piece of footwear is one of a footwear, a boot or a sandal.
[7]
The method of claim 1, wherein the customized footwear model includes at least one of a bend line pattern, a zone of changed thickness, or a cellular structure.
[8]
The method of claim 2, wherein the piece of footwear includes at least one of a bend line pattern, a zone of changed thickness, or a cellular structure.
[9]
The method of claim 2, wherein the piece of footwear is configured with a view to changing a biomechanical action of the user's foot.
[10]
The method of claim 2, wherein the piece of footwear is configured with a view to improving a static weight distribution of a user's foot.
[11]
A device configured with a view to creating a piece of footwear, comprising: a data collection containing models of footwear templates and executable software; a sensor configured to create user data; and a processor in data communication with the data set and the sensor, wherein the processor is configured to execute the software and direct the device to: receive user data associated with a user; generating a user model based on the received user data; determining one or more corrective aspects based on the user model, generating a customized footwear model that contains a certain corrective aspect; creating a piece of footwear based on the customized footwear model.
[12]
The device of claim 11, wherein the piece of footwear is created by means of an additive manufacturing technique.
[13]
The device of claim 11, wherein the user data includes one or more of foot pressure data, step data, body data, or image data.
[14]
The device of claim 11, wherein the processor is configured to execute the software and further leading the device to: determining one or more corrective aspects based on statistical data.
[15]
The device of claim 12, wherein the statistical data includes a statistical shape model.
[16]
The device of claim 15, wherein the piece of footwear is one of a footwear, a boot or a sandal.
[17]
The device of claim 11, wherein the bespoke footwear model includes at least one of a bend line pattern, a changed thickness zone "4", or a cellular structure.
[18]
The device of claim 12, wherein the piece of footwear includes at least one of a bend line pattern, a zone of changed thickness, or a cellular structure.
[19]
The device of claim 12, wherein the piece of footwear is configured with a view to changing a biomechanical action of the user's foot.
[20]
The device of claim 12, wherein the footwear piece is configured with a view to improving a static weight distribution of a user's foot.

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同族专利:

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公开号 | 公开日

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WO2015169941A1|2015-11-12|

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法律状态:
2018-06-15| FG| Patent granted|Effective date: 20160301 |

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2018-06-15| MM| Lapsed because of non-payment of the annual fee|Effective date: 20170731 |

优先权:

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申请号 | 申请日 | 专利标题

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US201461991318P| true| 2014-05-09|2014-05-09|

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US61/991318|2014-05-09|

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