Personalised inner shoe soles

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In this test case, the creation of footwear incorporating an eco-sustainable, 3D-printed insole has been achieved. This innovative insole has been crafted using a biomaterial specifically designed in the project using microfribes for 3D printing technology, yielding a material applicable to shoe soles as a result of our project.

Its optimal design could withstand the patient’s weight and have a therapeutic purpose, functioning similarly to the insole itself.  These demonstrators have been successfully validated through real patient testing, where patients have provided valuable feedback based on their experiences.

Facts & Figures 

  • Design prototypes
  • Selection of biopolymers (BioTPU)
  • Treatment and production of flax and hemp microfibres
  • Compounding BioTPU with hemp fibres
  • 3D-printing and characterizations of the 3D printed parts
  • Upper design and union
  • Validation of complete final demonstrators
  • Antibacterial testing
  • The material developed for the project meets the specifications and technical requirements of the sector.

Related pilot lines

Increasing efficiency in processing of nano-enabled biobased materials by additive manufacturing technologies

A unique heading prototype will allow surface modification while printing in one step.

What we want to achieve: The main benefits from this pilot line for SMEs and companies will include competitive costs of dedicated processing equipment to produce complex3D printed parts and products at a very competitive cost, unlocking a change in their manufacturing processes and reducing manufacturing time by more than 50%. Download pilot line pdf

Establishing of a development environment for bio-based particle foams

The Fraunhofer ICT particle foaming pilot line will enable a fully controlled development/ production environment for particle foams tailored to the needs of the respective customers with nano-scaled additives incorporation to (bio)polymers to increase functionality.

What we want to achieve:
  • Product ideas that exist in companies can be turned into products much faster with the help of the new and improved pilot line, which increases the innovation rate of companies in the bio sector.
  • Shorter development cycles and integrated real-time characterisation methods enable a better understanding of the material-property relationship for a new material.
Download pilot line pdf

Compounding and processing of nano-enabled bio-materials

The Extensional Flow Mixer METEOR (patented by IPC) is used to develop new formulations with an efficient dispersion of additives while reducing the overheating, and so the thermal degradation of sensitive material, like PLA.

What we want to achieve:
  • A quality control will be integrated thanks to an inline capillary rheometer to be able to optimize compounding parameters. Control compounding parameters for zero material degradation and optimize distribution of the micro and nano-fillers.
  • Inline integration of 3D printing filament at 2 diameters 1.75 and 2.85 mm. Additionally, a flexible cooling system will be implemented with water or air for water-sensitive materials.
Download pilot line pdf

Processing & modification of micro natural fibres

Optimisation natural microfibers flax or hemps as an important component of biocomposites.

What we want to achieve:
  • The fibers can show high adhesion to any polymer matrices and can be functionalised by different method to meet final requirements.
  • There is lack of such raw materials on the markets. Small fiber dimension allows to produce precise composite elements.
Download pilot line pdf