Method for creating custom orthopedic supports from computerized data inputs

• US 9,910,425 B2
• Filed: 08/31/2016
• Issued: 03/06/2018
• Est. Priority Date: 04/21/2006
• Status: Active Grant

• Current Assignee: Donald Spector
• Original Assignee: Donald Spector
• Inventors: Spector, Donald
• Primary Examiner(s): Lin, Jason
• Application Number:
  US15/252,892
• Publication Number:
  US 20170017230A1
• Time in Patent Office: 552 Days
• Field of Search: None
• CPC Class Codes: A43B 17/00 Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
• CPC Class Codes: A43B 7/141 having an anatomical or curved form
• 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: A61B 5/1072 measuring distances on the body, e.g. measuring length, height or thickness A61B5/1076 takes precedence
• CPC Class Codes: A61B 6/50 specially adapted for specific body parts; specially adapted for specific clinical applications
• CPC Class Codes: A61B 6/505 for diagnosis of bone
• CPC Class Codes: A61B 6/5217 extracting a diagnostic or physiological parameter from medical diagnostic data
• CPC Class Codes: A61F 5/14 Special medical insertions for shoes for flat-feet, club-feet or the like
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G16H 50/30 for calculating health indices; for individual health risk assessment

Abstract

Systems and methods of measuring feet and designing and creating orthopedic inserts are described. A leg length discrepancy of a user is measured and this data, along with foot size are input into a computer. The computer then creates a computer model of a custom shoe insert based on this information. The computer model is then sent to a 3D printer to print the insert. The insert consists of a base insert with partial correction, and several additional layers that are added successively over time until a full correction is obtained. This eliminates any pain associated with a fully corrective insert, and allows the body to adjust gradually to the correction.

Claims

1. A method of developing at least one orthopedic insert for footwear used by a person, the method comprising:

measuring and analyzing a spinal column and leg length of the person using digital X-rays;

measuring a foot size and shape of a person;

receiving in a computer data defining spinal abnormalities and leg length discrepancy as well as foot size and shape of the person;

designing in the computer via a processor a computer model of an orthopedic insert based on the data input to the computer, the orthopedic insert comprising a base insert having a partial corrective effect and a plurality of separate layers to be applied on top of the base insert, each one of said plurality of separate layers being configured to achieve a further corrective effect when applied on top of the base insert;

transmitting the computer model of the orthopedic insert from the computer to a manufacturing device comprising a 3D printer; and

making the orthopedic insert comprising the base insert and and plurality of separate layers with the manufacturing device based on the computer model in a single printing process, applying adhesive to each one of the plurality of separate layers, and applying a peel-off backing to the adhesive on each one of the separate layers, so that the separate layers can be applied to the base layer at later times.

2. The method according to claim 1, wherein the steps of receiving include receiving the data regarding leg length discrepancy and foot size via a transmission over the internet.

3. The method according to claim 1, wherein the step of receiving includes receiving data regarding a number of additional layers to be manufactured for attachment to the base insert.