Physical Property of 3D-Printed N-Pointed Star-Shaped Outsole Prepared by FDM 3D Printer Using the Lightweight TPU

Abstract

This investigation has shown the feasibility of modulation in physical properties for multiple outsole designs with 3-, 4-, and 6-pointed star-shaped patterns and various thicknesses for 5, 7.5, and 10 mm, which were fabricated with a FDM 3D printer using lightweight TPU filament, where the physical and foot pressure distribution properties were evaluated to confirm the best quality and comfort outsole. Through varying the structural pattern designs in combination with optimal 3D-printing parameters, the physical properties of the TPU LW-3, 4, and 6-PS outsoles were confirmed with enhanced properties along with increased thicknesses. In this study, the morphology images revealed a lower foaming state, a better-fused interlayer, and fewer microvoids in the TPU LW-3, 4, and 6-PS outsole, as the thickness developed, indicating enhanced density and rigidity. The best physical property was confirmed at LW 3-PS-10 with 0.706 specific gravity, 68.3 g weight, 0.232 static coefficient and 0.199 dynamic coefficient, 236% NSB abrasion, 127 DIN abrasion, 30% ball drop and 28% pendulum resilience, verifying the most high-quality, safe, and durable prototype. Regarding comfort, the 3-PS-10 also was regarded as comfortable concerning the wearable parts by virtue of its excellent physical properties, as well as its having the largest pressure area and the lower pressure force; meanwhile, the 4PS and 6PS also exhibited similar conditions for different thicknesses. Since not much distinct difference in pressure distribution compared to others was exhibited, it is suggested to explore optimization solutions to update the comfort of the footwear in future research.

Assessment of consolidative multi-criteria decision making (C-MCDM) algorithms for optimal mapping of polymer materials in additive manufacturing: A case study of orthotic application

“…Improved production processes and the utilization of higher-quality materials can limit amputee risks and lower maintenance costs while simultaneously enhancing the fitting and usefulness. The material type of an orthotic device ultimately dictates its physical qualities, including adaptability, resilience, endurance, hardness, weight, and temperature tolerance [ 20 ]. However, selecting a material for orthotics should not be based just on one feature of the product's design.…”

Optimisation of printing parameters of fused filament fabrication and uniaxial compression failure analysis for four-point star-shaped structures

“…The star-shaped structures have also been demonstrated to exhibit negative refraction and self-collimation for applications in phononic crystals (vibration isolation and elastic waveguide) (Chang et al , 2019, Zhang et al , 2023), as well as tunable high and low frequency plane wave attenuation properties (Xin et al , 2021). These metamaterials have been fabricated through 3D printing technology such as FFF and their structural properties strongly depend on the 3D printing conditions (Chen and Lee, 2022). Despite these reports, there are no published studies on the optimisation of FDM of four-point star-shaped and related metamaterials.…”