SYSTEM AND METHOD FOR GENERATING CUSTOM SHOE INSOLE

• US 20170255185A1
• Filed: 02/27/2017
• Published: 09/07/2017
• Est. Priority Date: 03/01/2016
• Status: Abandoned Application

• Current Assignee: Glen D. Hinshaw
• Original Assignee: Glen D. Hinshaw
• Inventors: Hinshaw, Glen D.
• Application Number:
  US15/444,139
• Publication Number:
  US 20170255185A1
• Time in Patent Office: Days
• CPC Class Codes: A43B 1/00 Footwear characterised by the material
• CPC Class Codes: A43B 13/00 Soles; Sole-and-heel integral units
• CPC Class Codes: A43D 1/025 comprising optical means, e.g. mirrors, photo-electric cells, for measuring or inspecting feet
• CPC Class Codes: A43D 2200/60 Computer aided manufacture of footwear, e.g. CAD or CAM
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/49023 3-D printing, layer of powder, add drops of binder in layer, new powder
• CPC Class Codes: G06F 30/20 Design optimisation, verification or simulation optimisation, verification or simulation of circuit designs G06F30/30
• CPC Class Codes: G06N 5/022 Knowledge engineering; Knowledge acquisition

Abstract

The present invention is a system and method for measuring and generating a customized foot orthotic insole that may be inserted into footwear, to reposition the foot to that referenced neutral position or as close to that position as the individual can tolerate. The present invention can scan, manufacture, and dispense the custom insole at an integrated station that can be located in a specialist'"'"'s office, but also in retail space, malls, airports, etc. The invention allows a customer to have his or her foot scanned using different types of three dimensional scanning or pressure scanning devices, whereupon the information from the scan(s) is/are fed to a semi-automatic design system, where computer programs and specialized AI algorithms create a custom insole design.

Claims

1. A method for fabricating a custom shoe insole, comprising:

providing a mobile kiosk;

scanning a customer'"'"'s feet at the mobile kiosk;

communicating scanning data to a three dimensional printer at the kiosk;

printing a custom shoe insole using the three dimensional printer from the scanning data; and

covering the printed custom insole with a flexible cover.

cutting the covered, printed custom insole at the kiosk.

2. The method for fabricating a custom shoe insole of claim 1, wherein the scanning step comprises an optical scanner.

3. The method for fabricating a custom shoe insole of claim 2, wherein the scanning step further comprises a pressure scanning.

4. The method for fabricating a custom shoe insole of claim 3, wherein the pressure scanning is a static measurement.

5. The method for fabricating a custom shoe insole of claim 4, wherein the pressure scanning also includes a dynamic measurement.

6. The method for fabricating a custom shoe insole of claim 1, further comprising a step of displaying on a monitor a progress of the printed step.

7. The method for fabricating a custom shoe insole of claim 1, wherein the three dimensional printer is connected to a remote data storage providing supplemental information on insole manufacturing methodologies, and wherein the three dimensional printer accesses the remote data storage to obtain the supplemental information prior to initiating the printing step.

8. The method for fabricating a custom shoe insole of claim 7, where the remote data storage is the Cloud.

9. The method for fabricating a custom shoe insole of claim 7, where the supplemental information includes three dimensional printing instructions.

10. The method for fabricating a custom shoe insole of claim 7, where the supplemental information includes customer information.

11. The method for fabricating a custom shoe insole of claim 1, wherein the scanning step uses a thermal film to profile the customer'"'"'s feet.

12. The method for fabricating a custom shoe insole of claim 1, further comprising a step of entering instructions via a graphic user interface prior to customizing a printing operation.

13. The method for fabricating a custom shoe insole of claim 1, further comprising a step of using artificial intelligence to design the insole.

14. The method for fabricating a custom shoe insole of claim 1, further comprising using a conductive material to fabricate the insole, and acquiring wireless feedback from the conductive insole to improve subsequent printing operations.

15. The method for fabricating a custom shoe insole of claim 1, further comprising providing a questionnaire to the customer prior to initiating the printing step, and using answers from the questionnaire to influence a selection of the custom insole.

16. The method for fabricating a custom shoe insole of claim 1, further comprising embedding a sensor into the insole for activity tracking.

17. The method for fabricating a custom shoe insole of claim 1, wherein a design process includes a first stage where a feature map is generated to determine modifications to a baseline model, and a second stage where the feature map is combined with scanned data and material characteristics to provide a final design model of the insole.

18. The method for fabricating a custom shoe insole of claim 1, further comprising generating a unique optical recognition code for each pair of insoles designed, and assigning the unique optical recognition code of the insoles to the printer to retrieve a print file associated with the designated insoles.

19. The method for fabricating a custom shoe insole of claim 1, further comprising automatically issuing an alert to a customer when a fabrication process is completed.

20. The method for fabricating a custom shoe insole of claim 1, wherein the cutting step is performed using a guided laser.

21. The method for fabricating a custom shoe insole of claim 20, wherein the guided laser is incorporated into a printer head used in the printing step.

22. The method for fabricating a custom shoe insole of claim 1, wherein the scanning step and printing step are controlled by a hand held device.

23. The method for fabricating a custom shoe insole of claim 1, wherein the printing step is used to create a filament structure that is combined with a wire mesh exoskeleton.

24. A mobile kiosk for producing a custom shoe insole, comprising:

a floor;

a scanner mounted in said floor;

a kiosk monument;

a three dimensional printer within the kiosk monument;

a network interconnecting the scanner, the three dimensional printer, and a remote data storage, the network including at least one local data storage; and

a network connectivity allowing the network to access the remote data storage and the internet;

whereby data from the scanner is combined with data retrieved from the local data storage to design a custom shoe insole, whereupon instructions are received by the three dimensional printer for carrying out a printing operation to fabricate the custom shoe insole.

25. The mobile kiosk of claim 24, further comprising a cover and cutting station where a printed insole is covered with a top cover and then cut using a laser or bladed instrument controlled by a computer with automatic alignment.

26. The mobile kiosk of claim 24, further comprising a monitor for displaying a progress of the printing operation.

27. The mobile kiosk of claim 24, wherein the scanner comprises an optical scanner.

28. The mobile kiosk of claim 24, wherein said kiosk monument includes a sample display case.

29. The mobile kiosk of claim 25, further comprising a printer filament feed compartment adjacent the three dimensional printer.