3D Printing Using Foaming TPU For Custom Insole Orthotics

This project explores the impact of printing temperature on the compressive properties of foaming Thermoplastic Polyurethane (TPU) in additive manufacturing. The objective is to manipulate porosity through temperature variations to enhance mechanical properties for custom 3D-printed insoles. By following ASTM D695 standards, both cylindrical and dogbone samples will be fabricated and tested under compression, modulus, and creep conditions, with comparative analysis between foaming and 2 non foaming TPU materials to evaluate differences in mechanical properties. The study aims to establish an optimal balance between density, elasticity, and structural integrity to inform the design of lightweight, cost-effective, and sustainable insoles, as well as to evaluate the mechanical differences between foaming and non-foaming TPU . Experimental findings will be visualized through stress-strain graphs and deformation analysis, contributing to advancements in personalized footwear and broader applications in healthcare and consumer products.