Therapeutic 3D-Printed Insole with Vibration Sensing

Abstract

Foot-related conditions such as diabetic nephropathy, plantar fasciitis, and musculoskeletal disorders can significantly impair mobility and increase the risk of foot ulcers and falls. This study presents the development of a customization, therapeutic 3D-printed insole integrated with vibration sensing technology to address these challenges. Designed using Sketch-up and fabricated with TPU material through precision slicing in UltimakerCura, the insole is tailored to the user\'s foot anatomy for optimal fit and comfort. A vibration motor and sensor are embedded to monitor pressure changes, foot movement, and gait abnormalities, providing real-time feedback for preventive care and rehabilitation. Post-processing techniques enhance durability and usability. By combining digital fabrication with smart biomechanics, this innovative insole offers a cost-effective, non-invasive solution for continuous foot health monitoring, supporting personalized healthcare, fall prevention, and athletic performance optimization.

Introduction

I. Introduction
Foot health is essential for mobility, balance, and quality of life. Conditions like diabetic neuropathy, plantar fasciitis, and musculoskeletal disorders often lead to gait issues, reduced sensory feedback, and higher fall risk. This has driven the development of personalized solutions that combine comfort with real-time monitoring and therapy.

Advancements in Technology:

• 3D-printed insoles made with flexible TPU allow customization for individual foot anatomy.

• Smart sensors integrated into these insoles enable functions like gait analysis and pressure monitoring.

• This study presents a 3D-printed insole embedded with vibration sensing for real-time feedback and therapeutic benefits, fabricated using tools like SketchUp and Ultimaker Cura.

II. Related Works

1. Customized Insoles for Musculoskeletal Issues:
   A study with 200 patients showed that 3D-printed insoles (using SolidWorks and TPU) improved pressure distribution, comfort, and pain relief over 6–18 months.

2. Vibrating Insoles for Diabetic Neuropathy:
   A randomized study on 18 DPN patients showed vibrating insoles improved standing balance, gait, and muscle activity.

3. Running Insole Case Study:
   A recreational runner tested TPU-based 3D-printed insoles created using Artec Eva scanner and GensoleEasyCAD. Results showed enhanced comfort, support, and reduced pain.

4. Review of 3D-Printed vs Traditional Insoles:
   3D-printed insoles offered superior pressure redistribution, pain relief, and customization for conditions like flatfoot, plantar fasciitis, and diabetic ulcers.

5. Pressure-Sensing Insole via Multi-material 3D Printing:
   Insoles embedded with capacitive pressure sensors tracked foot pressure and gait patterns with good durability and accuracy.

6. Orthopedic Insoles for Diabetic Patients:
   Customized 3D-printed insoles (via Gensole and flexible polymers) were tested with pressure sensors. They showed improved pressure offloading and gait correction.

III. Methodology

• A micro vibration motor (80–120 Hz) is placed under the arch/heel for therapeutic feedback.

• The system includes a rechargeable battery and a switch-controlled circuit.

• Users tested the device daily (10–15 min), reporting improved comfort and reduced fatigue.

IV. Block Diagrams

Two block diagrams illustrate:

1. The design method for creating the 3D-printed insole.

2. The vibration sensing mechanism for therapeutic and diagnostic feedback.

V. Hardware Description

• Arduino UNO: Controls sensors/motors; easy-to-use for prototyping.

• Micro Vibration Motor (ERM): Small motor generating therapeutic vibrations; ideal for wearable use.

• SW-420 Vibration Sensor: Detects foot movements and abnormalities using a spring sensor and LM393 comparator.

VI. Software Description

• Arduino IDE: For coding and uploading programs to hardware.

• SolidWorks: For detailed 3D modeling of insoles.

• STL Format: Used for 3D printing the insole geometry.

• Ultimaker Cura: Slicing software to convert models to G-code for printing.

• NodeMCU Programming: For IoT-based functionality using the ESP8266 Wi-Fi module via Arduino IDE.

Conclusion

Vibration therapy to the foot has proven to be an effective, non-invasive method for enhancing blood circulation, reducing pain, and promoting muscular relaxation. Through the application of targeted, low-frequency mechanical stimulation, this approach supports natural healing processes and improves comfort, particularly for individuals experiencing chronic foot conditions such as neuropathy, plantar fasciitis, arthritis, and fatigue due to extended standing or walking. It stimulates sensory receptors and mechanoreceptors in the foot sole, aiding in the restoration of proprioceptive feedback and balance control, which are often impaired in patients with neurological or musculoskeletal disorders. Furthermore, vibration therapy helps reduce inflammation, alleviate stiffness, and increase local tissue oxygenation, contributing to faster recovery and improved foot function. Its simplicity, safety, and drug-free nature make it a practical therapeutic solution for daily foot care, preventive health, post-exercise recovery, and long-term wellness. The integration of vibration therapy into smart insoles or foot platforms also enables personalized intensity adjustment and real-time monitoring, further enhancing its clinical and home-based applications.

References

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Copyright

Copyright © 2025 Ms. M Aruna, Priyadharshini B, Shanmugavalli S. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.