TECHNICAL FIELD

[0001] The present invention generally relates to a customized insole manufacturing system.

BACKGROUND

[0002] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

[0003] Individuals with foot soreness can consult with podiatrists that prescribe custom functional foot orthoses or insoles.

[0004] In some cases, individuals in remote areas cannot readily consult with a podiatrist for suitable treatment. In other cases, individuals will obtain generic insoles with limited benefit to save on the cost of a podiatrist.

[0005] The preferred embodiment provides improved access to customized insoles.

SUMMARY OF THE INVENTION

[0006] According to one aspect of the present invention, there is provided a customized insole manufacturing system for manufacturing a footwear insole, the system including:

an image capture device for capturing multiple images of at least one foot;

an insole designer for creating an insole design for the foot using the captured images; and

a three-dimensional (3D) printer for 3D printing the footwear insole in accordance with the insole design.

[0007] Advantageously, the customized footwear insole may be simply posted to the individual thereby providing access to customized insoles without the need to consult with a podiatrist. [0008] The multiple captured images may include at least three images capturing different aspects of the foot. The multiple captured images typically provide

measurement of the whole foot so that a more accurate insole design can be created. Preferably, the insole is an orthotic insole.

[0009] The insole designer may include an image processor for processing the images. The image processor may use artificial intelligence. The images may include still images or photographs of the foot. The images may further include video of the foot when walking representing the person’s gait so that a more accurate insole design can be created.

[00010] The images may include a standing relaxed calcaneal position image. The image processor may determine an angle between a bisection line of a posterior heel bone (calcaneus) of the foot and a perpendicular line extending from the ground upon which the foot rests to determine an angle of the insole.

[00011] The images may include a single stance long arch profile image. The image processor may determine arch anatomical landmarks in the profile image to determine a support contour of the insole. The images may include another single stance long arch profile image for the other foot.

[00012] The images may include another single stance long arch profile image when the first metatarsal phalangeal joint is in end range flexion. The image processor may determine adjustments to the insole design to avoid impeding movement of the first metatarsal phalangeal joint. The adjustments may be based upon a comparison of the single stance long arch profile image with the other single stance long arch profile image when the first metatarsal phalangeal joint is in end range flexion. The images may include another single stance long arch profile image when the first metatarsal phalangeal joint is in end range flexion.

[00013] The system may further include an advisor for providing advice based upon the captured images. The images may include a double stance squat position image. The advisor may provide advice based upon a comparison of the double stance squat position image and a standing relaxed calcaneal position image. [00014] The image capture device may include a phone camera, tablet camera, or other internet enabled portable device.

[00015] According to another aspect of the present invention, there is provided a customized insole manufacturing method for manufacturing a footwear insole, the method including the steps of:

capturing multiple images of at least one foot;

creating an insole design for the foot using the captured images; and

three-dimensional (3D) printing the footwear insole in accordance with the insole design.

[00016] According to another aspect of the present invention, there is provided a three-dimensional (3D) printed footwear insole manufactured in accordance with the foregoing method.

[00017] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[00018] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[00019] Figure 1 is a block diagram of a customized insole manufacturing system in accordance with an embodiment of the present invention;

[00020] Figure 2 is a flowchart showing an insole manufacturing method in accordance with an embodiment of the present invention; and

[00021] Figure 3 is a standing relaxed calcaneal position image;

[00022] Figure 4 is a double stance squat position image; [00023] Figure 5 is a left-foot single stance long arch profile image; and

[00024] Figure 6 is another left-foot single stance long arch profile image when the first metatarsal phalangeal joint is in end range flexion.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[00025] According to an embodiment of the present invention, there is provided a customized insole manufacturing system 100 for manufacturing a footwear insole 102 as shown in Figure 1.

[00026] The system 100 includes a camera of a smart phone 104 (i.e. image capture device) for capturing one or more images of feet 106. An insole designer server 108 is provided for creating an insole design 110 for the feet 106 using the captured images. The system 100 also includes a three-dimensional (3D) printer 1 12 for 3D printing the footwear insole 102 in accordance with the insole design 1 10.

[00027] Advantageously, the customized footwear insole 106 is simply posted to the individual via postal mail 1 14 (i.e. transporter) thereby providing access to customized insoles 102 without the need to consult with a podiatrist.

[00028] The insole designer server 108 includes an image processor 1 16 for processing the captured images to determine landmarks of the feet 106. The image processor 1 16 utilises artificial intelligence (Al) in the form of an expert system, neural network or fuzzy logic to determine landmarks of the feet 106 in the captured image using an Al library in the database 118.

[00029] The web server 108 further includes an advisor 120 for providing podiatric advice based upon the captured images. Further, the web server 108 includes an orderer 122 for ordering the insole 102 once payment has been made by the individual.

[00030] The phone 104 executes application software (an App) to capture the images and forward them to the web server 108 for image processing. The web server 108 then forwards the insole design 1 10, in electronic print format, to the three-dimensional (3D) printer 1 12 for printing the insole 102. [00031] A method 200 for manufacturing the customized insole 102 is now described with reference to Figure 2.

[00032] At step 202, the phone 104 captures still images (photographs) of the feet 106, as well as video of the feet 106 when walking. The App guides the individual into capturing the images 300 for image processing at step 204 as follows.

[00033] Standing relaxed calcaneal position

[00034] As shown in Figure 3, the images captured by phone 104 include a standing relaxed calcaneal position image 300.

[00035] The image processor 116 processes the image 300 and identifies the anatomical landmarks 302. The bisection of the posterior heel bone (calcaneus) allows a measurement to be taken of the angle in which this bisection line presents itself in relation to a perpendicular line from the ground in which the heel is standing. The angle can present as a varus (lateral) presentation or as a valgus (medial) presentation. The degree of varus/valgus determines the angle at which the custom functional orthotic 102 is posted (wedged). Artificial intelligence is used to determine this bisection line and allows a precise measurement to be determined.

[00036] Double stance squat position

[00037] As shown in Figure 4, the images captured by phone 104 include a double stance squat position image 400.

[00038] When the lower leg (tibia) moves forward over the foot as it would when walking or running the available ankle range determines the efficiency of this movement pattern. If the ankle range is restricted (ankle equinus) the primary compensation pathway for the body is to promote the foot into internal rotation (pronation). This pronation movement will see an exaggerated valgus position of the posterior heel bisection.

[00039] This is a measurable determinant by comparing the standing relaxed calcaneal position to the double stance squat position. The pathway of care to the patient will vary depending on the degree of difference between the two measurements. [00040] The processor artificial intelligence can determine this difference, and highlight to the patient this particular inadequacy and promote a clinically relevant treatment pathway. The advisor 120 provides advice based upon the comparison of the double stance squat position image 400 and a standing relaxed calcaneal position image 300.

[00041] Single stance long arch architecture/profile

[00042] As shown in Figure 5, the images captured by phone 104 include a left-foot single stance long arch profile image 500.

[00043] An important component in orthotic delivery is to determine the anatomical architecture and profile of the medial longitudinal arch. In a single standing posture, the processor 1 16 determines four key anatomical landmarks 302 that represent the dynamic profile of the patient's medial longitudinal arch. These measurements determine key differences between left and right feet 106 and allow the customisation of each single custom functional orthotic 102 based on these landmarks 302. The artificial intelligence determines these landmarks 302 and as a result delivers precise

measurements in the delivery of the patient's custom functional orthotic device 102 which represents a significant technical effect. An ideal support contour of the insole 102 is determined.

[00044] Similarly, the processor 1 16 image processes a right-foot single stance long arch profile image.

[00045] Single stance long arch architecture/profile when first metatarsal phalangeal joint is in end range flexion

[00046] As shown in Figure 6, the images captured by phone 104 include another left-foot single stance long arch profile image 600 when the first metatarsal phalangeal joint 602 is in end range flexion.

[00047] A principle in foot function relates to a biomechanical pathway referred to as the "windlass" effect. This effect highlights the need to allow the foot 106 to efficiently recruit certain soft tissue structures within the foot 106 to promote appropriate strength and stability whilst moving the body's centre of mass over it. A key principle within the "windlass" effect is to ensure that the range of motion at the level of the first metatarsal phalangeal joint 602 is unimpeded and protected. It is critical that the orthotic appliance 102 does not undermine this key biomechanical principle.

[00048] The medial longitudinal arch profile changes in certain patients when the first metatarsal phalangeal joint 602 is fully flexed. This patient group is identified as the custom functional orthotic prescription will need appropriate prescription alterations. By comparing medial longitudinal arch profile lengths (single stance image 500 vs single stance with toe flexion image 600) this patient group can be determined.

[00049] The image processor artificial intelligence can determine this difference and allows appropriate prescription allowances to ensure that the custom functional orthotic 102 optimises foot function.

[00050] Similarly, the processor 1 16 image processes a right-foot single stance long arch profile image when the first metatarsal phalangeal joint is in end range flexion.

[00051] At step 206, the image processor 1 16 creates the insole design 110 for both the feet 106 using the foregoing captured images 300, 400, 500, 600.

[00052] At step 208, the orderer 122 orders the insole 102 based upon the design 1 10 once the individuals payment has been verified. In particular, the electronic insole design 1 10 is forwarded in the form or printer data to the three-dimensional (3D) printer 1 12.

[00053] At step 210, the 3D printer 1 12 prints the footwear insoles 102 in accordance with the received insole design 1 10.

[00054] At step 212, the postal transporter 1 14 transports and delivers the printed footwear insoles 102 to the individual for treatment of the feet 106.

[00055] A person skilled in the art will appreciate that many embodiments and variations can be made without departing from the ambit of the present invention.

[00056] In one embodiment, captured and processed images further include video of the feet 106 when walking (5 steps). [00057] The image capture device for capturing images can include a tablet camera, or other internet enabled portable device.

[00058] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.

[00059] Reference throughout this specification to‘one embodiment’ or‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases‘in one embodiment’ or‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.