Design of Volumetric 3D-Printed Orthotic Insoles for Plantar Pressure Offloading and Preventing Diabetic Foot Ulcers

Diabetic foot ulcers (DFUs) are a serious complication of diabetes, often resulting from sustained high plantar pressure and poor foot biomechanics. Traditional orthotic insoles offer limited customization and may fail to adequately redistribute plantar pressure, particularly in high-risk diabetic patients. This study presents the design and development of volumetric 3D-printed orthotic insoles tailored to individual foot morphology and pressure distribution. Using patient-specific foot measurements and plantar pressure mapping, insoles were designed with variable-density lattice structures to provide targeted offloading and enhanced biomechanical support. Finite Element Analysis (FEA) was employed to optimize structural performance, ensuring effective pressure redistribution while maintaining user comfort and durability. The prototypes were fabricated using flexible, biocompatible materials through additive manufacturing techniques. Preliminary testing demonstrated significant reductions in peak plantar pressure in critical regions such as the heel and metatarsal heads. The proposed approach highlights the potential of personalised 3D-printed insoles in preventing DFUS by offering improved pressure offloading, enhanced comfort, and better adherence to foot contours. This work underscores the value of integrating biomechanical modelling and advanced manufacturing for patient-specific diabetic foot care solutions.