Problems of conventional custom SHOE insoles:
- CNC machining EVA foam produces lot of waste and requires additional finishing stages like gluing and polishing.
- EVA foam is non breathable causing retained moisture
- Extended production time
- Relatively high price
Depicted (from left to right): 1. Manual work - gluing and polishing, 2. CNC machining 3. Unpleasant worn insole 4. Waste
WhAT IS Gyroid? How is it related to 3D printing?
Gyroid is porous, lightweight and advanced microstructure found in sea-urchin skeleton and butterfly wings. It features no joints or discontinuities allowing great unified air and liquid permeability and distributing stress concentration equally in all directions.
Because of its complexity, without Additive Manufacturing technology (3D printing) it was nearly impossible to recreate such structure. Although the full potential of TPMS* Gyroid structure is not entirely revealed to public, we are witnessing many benefits and spectrum of its applications, but its most commonly used as infill structure in 3D printing because:
1. It is an almost isotropic structure, which means that it is equally resistant to forces coming from all directions.
2. Doesn't need supports - TPMS structures are self-supporting in nature, making them perfect especially for FDM (extrusion based) manufacturing.
3. Gyroid's weight is highly reduced - eg. 30% lighter than honeycombs
4. Less material consumption with better performance
5. Shorter printing times
6. Great liquid and air flow - its porosity allows unified distribution in all directions
3D printing as revolutionary technology amongst many benefits allowed us widespread accessibility, waste reduction and ability to personalize our everyday objects faster at reduced cost.
*TPMS - triply periodic minimal surface
Credits to @WildRoseBuilds for gyroid 3d printing timelapse
Isometric and Front view showing porosity of TPMS Gyroid structure (Walled and Full)
DIGITAL FOAM?
Digital foam is "preprogrammed" flexible material, optimized for best performance.
Name is coined by EOS GmbH company. It is dedicated for 3D printing and mass customization which stands for serial production of end-use products adjusted for each individual.
"Digital foam found its way into 3D printing. It allows flexible material to be precisely adjusted and manufacture more comfortable, safer and lighter products that can be individually customized." - EOS GmbH, https://www.eos.info/en/innovations/think-hub/digital-foam
With help of new generation engineering software such as nTopology, I was able to variably adjust flexible material properties by combining various types, sizes, densities and thicknesses of gyroid structures with smooth geometry transitions. Those properties can significantly reflect on product performance, comfort and safety.
One product from one process, one material with infinite possibilities.
Source: EOS GMBH - https://www.eos.info/en/innovations/think-hub/digital-foam
Variable density by combining more flexible Walled and more rigid Full TPMS Gyroid for achieving optimal area for comfort, support and structure stiffness
PERSONALIZED GYROID INSOLE (2021)
Concept from BA thesis
by Hamza Bavčić
Product design department - Academy of Fine Arts Sarajevo - Mentor: prof. Jasna Mujkić
