Product Development and Management

(MEE3501)

Final Review

By
Akash Konar (20BME0024)
Vedant Sachin Kulkarni (20BME0030)
Advait Amol Bawdekar (20BME0076)
 Product #1: Collapsible Cover Casing for sunglasses and spectacles
Abstract
Traditional casings are often bothersome when it comes keeping them somewhere or carrying them
while transiting anywhere. Therefore, a collapsible or foldable sunglasses cover arise as the need of the
hour.

The casing will be triangular in shape and magnetic bar will be used as the closing mechanism. The
casing will also be sturdy enough to protect the eyewear. Its foldable characteristic would be helpful in
carrying the case in bags or pockets very easily.
Justification
Surveys indicate that around 60% of the world’s population uses spectacles for aid in vision and almost
every person uses a pair of sunglasses. The extensive use of these eyewear supports the need of cover
casings in order to safely keep them as the glasses are delicate. These casings often take up a lot of space
and are also inconvenient to store somewhere due to their design and shape. This is the primary demerit
of the traditional casings that spark the need to foldable or collapsible casings.

Practical applications
This product is very useful as it can be used by every person in their day-to-day life. The hard case
eyeglass holder is manufactured to keep the glasses safe no matter what and the designs make it easier
for locating them. Due to a special lining, the case protects the lenses from scratches and its arms from
bending and breaking. The soft lining is also great for protecting the lenses from dirt and residue, thus
keeping them clean.
Problem statement
 This product aims to ease out problems people generally face with their eyewear casings. These casings
are heavy and occupy a lot of space making them difficult to carry when there is not a lot of space for
storage. They need to be light in weight and made up of sturdy material necessary for maintaining its
strength and protecting the lenses. To make it easily portable that too on a frequent basis, the product has
been appropriately designed.
Project objective
The primary goal is to produce a high-quality, assurance-based solution at a reduced and appropriate cost
that make clients’ lives easier by eliminating this very small but colossal problem. To put it simply, to
offer the convenience of perfect storage while reducing unnecessary space consumed by the product.
Expected deliverables
It is expected that this table will help everyone in their lives every minute. People will find it easier to
store the spectacles safely and carry them. When not in use it can be folded and kept aside. Each and
every individual can be considered as an end consumer of this product despite their age and profession.
This casing due to its design would occupy very little space when it is folded. Basically, eyewear come
in use extensively in everyone’s lives and so does eyewear casing Therefore, some good modification
can therefore make everyone’s lives better as they can make the best of what they do.

 Product #2: Design of insole for shoes with lattice structure.

Abstract
In the modern world with increasing fuel prices, more and more people are switching to public transport
and walking to commute from one place to another. Thus designing safer and more comfortable shoes is
necessary. Considering Lattice structures, due to their porous characteristic of lattice structures, it
presents a new class of energy absorption materials that offer flexibility in tailoring the response to
impulse loads over conventional materials. Thus, application of these types of lattice structure in in
insole of shoes would give a better and safer experience to the user. The conventional foam insoles and
in insole of shoes will be replaced with a better and suitable lattice structure with best load absorption
properties.

Justification
Walking and running are becoming increasingly popular. Considering my very own example, walking in
VIT for students from one class to other and to their hostels are very common. Due to this, many
students have developed calluses and shoe bites on their foot due to long-term use of existing shoes.
Thus designing a comfortable in insole with a property of distributing the pressure evenly about the foot
is necessary avoid calluses. A lattice structure due to its porous nature, evenly distribute these loads and
is safer with low impact penetration as compared with traditional shoe insoles. This makes it a more
effective solution for the problem.
Practical Applications
This approach of lattice-generated insole will replace the traditional shoe insole. Due to its energy
absorption and flexibility, it provides a more comfortable experience for the user. Casual walkers, sports
athlete, can use this. People belonging to any age groups from kids to elderly people also can use it. Due
to the porosity of the lattice structure the structure is resistant to any low impact penetrations such as
nails, rocks etc. This increases the safety of the shoes.

Problem Statement
Long-term walking or running is a very common cause for calluses and shoe bites. To avoid calluses, a
comfortable insole with the property of distributing pressure evenly across the foot is required. Because
of its porous nature, a lattice structure evenly distributes these loads and is safer with low impact
penetration when compared to traditional shoe insoles. As a result, it is a more effective solution to the
problem.
Project objective
The objective of the lattice implemented shoe insole and in insole is to find an appropriate lattice design
with the best load absorption properties as well as a material with good deformation recovery. FEA
analysis like Static Structural, Fatigue analysis would help us determine sufficient load bearing capacity
and residual stresses respectively. To put it simply to make a simple yet efficient design with maximum
comfort, load bearing capacity and minimum weight.
Expected deliverables
Using a biodegradable material for manufacturing the product will be an environment friendly and a
green product. People of all age groups can take advantages of this product. From school going children
to office workers. This is also an ideal product for athletes and sportsmen who engage in extensive
training and practice while wearing shoes. Incorporating a lattice structure in insole will help increase
the comfort level as well as provide protecti
 Product #3: Mountable Plastic Bag Sealer Station
Abstract
Plastic bags are used extensively in our day-to-day lives. Almost every essential grocery item that is
used in a classic Indian household comes sealed in a plastic bag. From salt and pepper to rice and flour,
everything comes in a plastic bag. Plastic bag seals have become a popular product to store products in
their original packing. The problem of storage and organisation arises with individual plastic bags. A
mountable plastic bag sealer station helps in organising, storing and sealing multiple plastic bags in an
orderly manner.

Justification
It becomes a tedious task to unpack all these groceries into containers every time you buy groceries. To
overcome this issue, plastic bag seals have become a popular product. Although this product does a great
job at sealing plastic bags, the organisation and storage of individual plastic bags is difficult. Using a
mountable plastic bag sealer station, multiple bags can be sealed and organised. This method is also
extremely inexpensive as the contents can be stored in its original plastic package itself. Hence, the
product is self-sufficient.
Practical Application
This product can be extensively used in pantries to store groceries, in bathrooms to store detergents, etc.
This product eliminates the use of bulky containers for items which can easily be stored in bags and frees
up space in your cabinets for other essentials.

Problem Statement
This product aims towards eliminating the need of bulky containers for storage of products and also
towards increasing the functionality of Plastic Bag Seals. The problems of storage and organisation that
arise with the use of individual plastic bag seals can be eliminated with the use of a station.
Project Objective
The primary objective of this product is to eliminate the need of bulky plastic containers. These
containers not only take up unnecessary space in storage cabinets but also increase the plastic waste. By
using the plastic packaging that comes along with the item bought, the use of excess plastic through the
means of plastic containers is eliminated. Lean manufacturing techniques can be inculcated to minimize
waste and increase productivity.
Expected Deliverables
The mountable station should be inexpensive, eco-friendly and easy to install. Bio-degradable materials
like Polylactic Acid (PLA) can be used to make the station and seals. The product should come along
with an installation manual, fasteners and essential tools like Allen keys to assemble the station. This
will make it easy for any user to easily assemble the station.
 Background Work and Literary survey
Product 1 - Design of insole for shoes with lattice structure.
1. Introduction
With the cost of petroleum rising in the modern world, more and more individuals are choosing to
travel by walking or taking public transportation. Thus, creating shoes that are both safer and more
comfortable is important. Lattice structures constitute a novel class of energy absorption materials
that allow versatility in modifying the response to impulse loads above traditional materials because
of their porous nature. Therefore, using these kinds of lattice structures in the footbed of shoes would
make the user's experience better and safer. A better and more appropriate lattice structure with the
best load absorption qualities will replace the conventional foam insoles and insoles of shoes.

2. Literature Review
An exceptional amount of innovation can be seen in the literature for the design of insole for
numerous applications aimed to assist people in better walking. The scope of creativity extends from
producing a design for medical applications like orthopaedic care to intelligent custom made
designing of insoles specific to various sporting events. The designs of the insoles for daily wear can
be designed on the basis of their BMI and pressure distribution of their weight on the people’s feet
[1-3]. Concerning various medical attributes leading to flat feet, a pioneering design has been
presented in [4]. New base designs are provided for people to customize the insole designs for
themselves for daily use in [5] and many such base designs are compared and analysed in [6] with
information on their manufacturability. Designs are also available for extremely specific applications
like improving landing mechanism for paratroopers [7]. In this case, the design is inspired by Cat
Paw Pad and Triply Periodic Minimal Surface (TPMS) bionic cushion soles. The concept of TPMS
can also be used in medical or specifically orthopaedic applications [8]. Lastly, prioritizing
distribution of plantar pressure specifically for diabetic patients, novel designs are proposed
consisting of two different types of insoles with personalized metamaterials in [9] while designs are
modified with Voronoi Structural design method in [10].
All of the literature presented can be seen very customer-oriented or application-oriented. An insole
design innovation is needed for generic purposes. Customization increases product cost while
application-oriented products can be of less usefulness in daily living. Whereas, a general novel
design that provides comfort to maximum users would be economical for producers as well as
customers. Therefore, after a thorough literature survey, two specific concepts have been selected
and are explained further.
3. Concepts
There are various types of lattice structures that can be chosen for the design of the shoe insole.
Every lattice structure has its own different set of mechanical properties. The optimum lattice
structure for a certain application can be chosen through the use of computerized simulation or
physical testing. The two lattice structures demonstrated here are Hexagonal Honeycomb Lattice
Structure and Inverted Square Honeycomb Lattice Structure. Honeycomb structures are well-
known for their mechanical properties and packing efficiency this reducing the overall weight of the
product.
Product 2 - Collapsible Cover Casing for sunglasses and spectacles
1. Introduction
When it comes to storage of the product or carrying the product while travelling, traditional casings
are frequently inconvenient. A retractable or folding sunglasses cover is therefore sorely needed. The
case will have a triangular form, and the closing mechanism will be a magnetic bar. Additionally, the
case will be strong enough to safeguard the eyeglasses. Due to its ability to be folded, the case would
be particularly convenient to carry in pockets or bags.

2. Literature Review
The designed product is not thoroughly mentioned in the literature but there are numerous related
patents. This product is inspired from rigid origami. The concept of rigid origami in general
applications conferring to movement of the product in one direction only constraining others i.e., 1
DOF, is explained in [11]. The most basic patent for a collapsible eyewear cover is [12] but the basic
drawback of the cover is that it is not rigid. There are various design novelties for rigid cases that
reduce unnecessary space [13,14]. Yet, the problem of unnecessary space consumption persists.
 Through the design presented in [15], the space the cover takes was drastically reduced as it was just
a lens cover but the protection of the frame is also very important. The protection of the frame is
ensured in [16] but the problem of space consumption when the glasses are not inside the case still
remains as the number of coverings increased. A very innovative design was produced by [17] and
the concept of hinging was applied but the design lacked some safety features as the focus of study
included many more features like a wallet or phone storage compartment. Finally, the closest patents
to the proposed product are [18-20]. All of these patents use buttoning mechanism to hold the
product closed. Advancements related are elaborated further in the document.
3. Concepts
Aiming to solve the problem of the buttoning mechanism which can result in frequent failures and be
of some discomfort when kept in pockets, the closing mechanism can be in two distinct ways -
Firstly, Velcro can be used to attest the opening flap to the rest of the box while the second case will
be addition of magnet and magnetic material. Both these mechanisms are extremely reliable and it
would not provide any additional discomfort. The figure provided above can be referred for both the
concepts.
 Application of FMEA and QFD for the Concepts.

FMEA For the Concepts

One type of product that has a high level of sales value is shoe insoles and eyewear cases. In order to
uncover reasons and causes of failures in the design process, the following study chooses the above
concepts as its study object. The report then suggests taking a proactive and methodical approach based
on the ideas of Failure Modes and Effects Analysis to resolve the issues (FMEA). The purpose of this
study is to avoid the potential reasons of the failure modes. As a result, the product's quality can be
guaranteed.

In this study, the research tool was an FMEA. First, failure modes are found. The severity, frequency,
and detection of these failure scenarios are then ranked, followed by an evaluation. Finally, these failure
types' probable causes and countermeasures are looked into. The following are the Occurrence,
Detection and Severity criteria for ranking: -
Table 1 : Criteria for Ranking Severity (S) in FMEA
Effect Severity Criteria Ranking
Failure mode causes the possibility of not meeting
government regulation and might be fatal to 10
product user.

Failure mode causes the possibility of not meeting

Extremely Serious government regulation and might endanger 9
product user but not fatal.

Failure mode causes the possibility of not meeting

government regulation but will not endanger 8
product user.

Failure mode may not meet buyer’s (retailer’s or

distributor’s) requirements. The buyer decides to
cancel or return the order of the product and will
7
not place any order to the company again.

Failure mode may not meet buyer’s (retailer’s or

distributor’s) requirements. The buyer decides to
cancel or return the order of the product but will
6
Very Serious
place orders to the company in the future.

Failure mode may not meet buyer’s (retailer’s or

distributor’s) requirements. However, the buyer
only asks compensation from the company and 5
will not return the order of the product and will
place orders to the company in the future.

Failure mode may make end user think that the

product has a bad quality.
4

Failure mode may cause production interruption

Serious and/or defective parts.
3

Failure mode will not cause production

interruption but some defective parts. May occur.
2

Failure mode will not cause noticeable negative

Less Serious effect.
1
 Table 2 : Criteria for Ranking Occurrence (O) in FMEA

Probability of
Failure Occurrence
Possible Failure Rates Criteria Ranking
Failure occurs once from 10 pairs of production
workpieces.
10
Very high: Failure is
almost unavoidable
Failure occurs once from 20 pairs of production
workpieces.
9

Failure occurs once from one 50 pairs of

High: Usually it production workpieces.
8
involves processes
that have failed
Failure occurs once from one 100 pairs of
frequently before
production workpieces.
7

Failure occurs once from 500 pairs of production

workpieces.
6

Moderate: Failure occurs once from 2,000 pairs of

Occasional failures production workpieces.
5

Failure occurs once from 10,000 pairs of

production workpieces.
4

Failure occurs once from 100,000 pairs of

production workpieces.
3
Low: Relatively few
failures
Failure occurs once from 10,00,000 pairs of
production workpieces.
2

Remote: Failure is Failure is detected and eliminated by the quality

unlikely inspection process
1

Table 3 : Criteria for Ranking Detection (D) in FMEA

Probability of
Failure Occurrence
Possible Failure Rates Criteria Ranking
Failure occurs once from 10 pairs of production
Almost impossible
workpieces.
10
Occurrence of the failure mode is random and it is
Very remote difficult to detect by using the extra and advanced 9
equipment.
The failure mode can be detected by using the
Remote
extra and advanced equipment carefully.
8
The failure mode can be detected by using the
Very Low
extra and advanced equipment easily.
7
The failure mode can be detected by using the
Low
extra and generated equipment carefully.
6
The failure mode can be detected by using the
Moderate
extra and generated equipment easily.
5
The failure mode can be detected by using the
Moderately High
standard equipment carefully.
4
The failure mode can be detected by using the
High
standard equipment easily.
3
The failure mode can be visually detected by the
Very High
quality inspector.
2
The failure mode can be visually detected by the
Almost Certain
operator.
1
FMEA of Inverted Square Honeycomb Lattice Structure Shoe Sole

O O
c D c D
S S
c e c e
e e
u t u t
Potential v Potential v
Item/ Potential Failure r Current Design e Recommended r e
Effect(s) of e Causes(s)/Mecha RPN Actions Taken e RPN
Function Mode r Controls c Action(s) r c
Failure r nism of Failure r
e ti e ti
it it
n o n o
y y
c n c n
e e

Breakage of Unequal pressure Finite Element

7 5 6 210 7 4 6 168
lattice links Distribution Analysis Exploring
Lattice Using Inverted Square
Poor Lattice Design better lattice
Structure Poor Shape Honeycomb Lattice Structure
Doesn’t return to 7 structures
Retention 5 Visual Inspection 4 140 7 4 4 112
its original shape
Property
Poor Strength
The material may 8 Finite Element
Characteristic of 4 6 192 8 3 6 144
disintegrate Analysis
material
Frequent wet High Moisture
Usage of Wrong Raw 7
soles or water Retention 6 Field Testing 5 210 Exploring Using TPU 75D as the 7 4 5 140
Raw Material Material for the
damage property better material material
Application
Sole damage Low Impact Finite Element
7 5 5 175 5 4 5 100
while running Strength Analysis
Insufficient Poor Cooling
6 6 Field testing 5 180 6 5 5 150
thermal comfort Characteristic
Poor Color
Exploring Used dye with better color
Retention 5 None 9 225 5 3 7 105
better Dyes retention property
Color Dye Selection Fading of Color 5 Property
Poor Quality of Changing dye
7 None 7 245 Using dye with better quality 5 4 6 120
Dye Used supplier
Designing without Changing
Insufficient Insufficient Implementing material with
consideration of 7 5 Field Testing 5 175 design or 7 3 5 105
Thermal comfort Breathability microporosity
thermal characteristics material
Design Designing a
Designing without
Foot Blisters or Concentration of more Designing a elevation near
consideration of 9 4 Field Testing 5 180 9 3 5 135
Callus Pressure at foot ergonomic the foot arch
pressure distribution
Design
FMEA of Hexagonal Honeycomb Lattice Structure Shoe Sole

O O
c D c D
S S
c e c e
e e
u t u t
Potential v Potential v
Item/ Potential Failure r Current Design e Recommended r e
Effect(s) of e Causes(s)/Mecha RPN Actions Taken e RPN
Function Mode r Controls c Action(s) r c
Failure ri nism of Failure r
e ti e ti
t it
n o n o
y y
c n c n
e e

Breakage of Unequal pressure Finite Element

7 4 6 168 7 2 5 70
lattice links Distribution Analysis Exploring
Lattice Implementing Diamond
Poor Lattice Design better lattice
Structure Poor Shape Lattice
Doesn’t return to 7 structures
Retention 4 Visual Inspection 4 112 7 2 3 42
its original shape
Property
Poor Strength
The material may 8 Finite Element
Characteristic of 3 6 144 8 2 5 80
disintegrate Analysis
material
Frequent wet High Moisture
Usage of Wrong Raw 7
soles or water Retention 4 Field Testing 5 140 Exploring Using TPU 95A as raw 7 1 3 21
Raw Material Material for the
damage property better material material
Application
Sole damage Low Impact Finite Element
5 4 5 100 3 4 4 48
while running Strength Analysis
Insufficient Poor Cooling
6 5 Field testing 5 150 6 1 3 18
thermal comfort Characteristic
Poor Color
Exploring Used dye with better color
Retention 3 None 7 105 5 2 5 50
better Dyes retention property
Color Dye Selection Fading of Color 5 Property
Poor Quality of Changing dye
4 None 6 120 Using dye with better quality 5 2 5 50
Dye Used supplier
Designing without Changing
Insufficient Insufficient
consideration of 7 3 Field Testing 5 105 design or Implementing 7 1 5 35
Thermal comfort Breathability
thermal characteristics material
Design Designing a
Designing without
Foot Blisters or Concentration of more
consideration of 9 3 Field Testing 5 135 Implementing 9 2 5 90
Callus Pressure at foot ergonomic
pressure distribution
Design
FMEA of Collapsible Cover Casing for sunglasses and spectacles with Velcro attested flap

O O
c D c D
S S
c e c e
e e
u t u t
Potential v Potential v
Item/ Potential Failure r Current Design e Recommended r e
Effect(s) of e Causes(s)/Mecha RPN Actions Taken e RPN
Function Mode r Controls c Action(s) r c
Failure r nism of Failure r
e ti e ti
it it
n o n o
y y
c n c n
e e

Stresses at the
5 Torsional test 3 105 7 3 2 42
bending edge
Better material
Case cannot be
Case frame Breakage of case 7 selection and Under consideration
used further Case has low stronger edging
compressive 4 Drop test 2 56 7 2 1 28
strength

Deterioration of
Better quality
the case’s look Bad quality of
Tearing of the cloth 6 5 Thread count test 4 120 cloth can be 6 1 4 24
and possible lens cloth
selected
damage
Case covering
Under consideration
cloth
Appropriate
Scratches on the Wrong material Textile surface
Cloth roughness 7 5 5 175 material can be 7 2 5 70
lenses selection test
selected

Sunglasses cannot Inherent problems Exploring

The case not closing ASTM D5170 Using Magnets for Closing
Velcro be stored in the 7 with Velcro and 6 5 210 better closing 7 4 5 140
properly test mechanism
case bad quality mechanism

Poor Color
Exploring Used dye with better color
Retention 3 None 7 105 5 2 5 50
better Dyes retention property
Property
Colour of
Dye Selection Fading of Color 5
covering cloth
Poor Quality of Changing dye
4 None 6 120 Using dye with better quality 5 2 5 50
Dye Used supplier
FMEA of Collapsible Cover Casing for sunglasses and spectacles with Magnet attested flap

O O
c D c D
S S
c e c e
e e
u t u t
Potential v Potential v
Item/ Potential Failure r Current Design e Recommended r e
Effect(s) of e Causes(s)/Mecha RPN Actions Taken e RPN
Function Mode r Controls c Action(s) r c
Failure r nism of Failure r
e ti e ti
it it
n o n o
y y
c n c n
e e

Stresses at the
5 Torsional test 3 105 7 3 2 42
bending edge
Better material
Case cannot be
Case frame Breakage of case 7 selection and Under consideration
used further
Case has low stronger edging
compressive 4 Drop test 2 56 7 2 2 28
strength
Damage to the
aesthetic of the Better quality
Bad quality of
Tearing of the cloth frame and 6 5 Thread count test 4 120 cloth can be 6 1 4 24
cloth
scratches on the selected
Case covering lenses Under consideration
cloth
Appropriate
Scratches on the Wrong material Textile surface
Cloth roughness 7 5 5 175 material can be 7 2 5 70
lenses selection test
selected
Problems in Protection can
Magnet bar Magnet breakage and
closing case and Inherent problems be provided in
for closing the loss in magnetic 6 4 Drop test 3 72 Using neodymium magnets 6 1 3 18
disturbance in the with magnet the design of
case properties
look of the case the case

Poor Color
Exploring Used dye with better color
Retention 3 None 7 105 5 2 5 50
better Dyes retention property
Property
Colour of
Dye Selection Fading of Color 5
covering cloth
Poor Quality of Changing dye
4 None 6 120 Using dye with better quality 5 2 5 50
Dye Used supplier
QFD of the Lattice Structure Shoe Sole
QFD of the Collapsible Cover Casing for sunglasses and spectacles
• Selection of Concepts
The product selected for the project is a Shoe Insole consisting of a Lattice Structure. Several concepts
were designed by varying the lattice structure of the insole. Two concepts were further studied and a
detailed Failure Mode and Effect Analysis (FMEA) was carried out for each of the concept design of the
chosen product.
The concepts consists of different lattice structures, namely, Hexagonal Honeycomb and Inverted Square
Honeycomb. Upon carrying out of a literature survey on the properties of various lattice structures, it
was found out that these lattice structures were stiff in nature and hence unsuitable for the insole of a
shoe. This property of the lattice structure was also found to be unsuitable upon studying the concepts
through Failure Mode and Effect Analysis (FMEA) and House of Quality (QFD).
Through literature survey, it was found out that a Diamond type of lattice is suitable for a shoe insole
due to its high displacement property which provides a soft surface for the foot. This provides great
comfort to the user in various applications such as walking, running, etc.
A solid insole was designed using Autodesk Fusion360. The insole was designed taking into
consideration the shape of a foot arch. The lattice was created on nTopology by converting the solid
body of the insole into a Volume Mesh, which was further converted into the desired lattice structure.

• Process conception document

Title: - Diamond lattice structured shoe insole
Date: - 14/11/22
Team members: -
Akash Konar (20BME0024), Vedant Kulkarni (20BME0030) and Advait Bawdekar (20BME0076)
Executive Summary: -
In the modern world, more and more people are preferring to walk or use public transportation due to the rising
expense of gasoline. Therefore, it's crucial to design shoes that are both safer and more comfortable. Because of
their porous character, lattice structures represent a distinct class of energy absorption materials that offer versatility
in changing the response to impulse loads above previous materials. Therefore, incorporating these kinds of lattice
structures into shoe footbeds would improve and increase user safety. The typical foam insoles and shoe insoles will
be replaced with a better and more appropriate lattice construction that has the best load absorption qualities.
Table of contents: -
i. Design problem and objectives
ii. Detailed design documentation
iii. Bill of Materials
iv. Ethical Considerations
v. Safety
vi. Conclusions
vii. Acknowledgement

1. Design problem and objectives: -

Calluses and shoe bites are two common foot conditions that can be caused by excessive walking or running. A
comfortable insole that has the ability to distribute pressure evenly across the foot is required in order to prevent
calluses from forming on the foot. In comparison to conventional shoe insoles, lattice structures are safer
because they allow for less impact penetration and more even distribution of loads due to the porous nature of
the structure. As a consequence of this, it is a solution to the issue that is more efficient.
The main objectives in designing lattice-implemented shoe insole are -
a. Finding a material that has good deformation recovery
b. Appropriately selecting lattice design that has the best load absorption properties using a FEA analysis, such
as a static structural analysis or a fatigue analysis, which assists determining the appropriate load bearing
capacity and, separately, the residual stresses.
c. Create a design that is uncomplicated yet effective, offering maximum comfort along with maximum load
bearing capacity and minimum weight.

2. Detailed design documentation: -

The Design of the shoe insole was started by considering a stardised topography of the foot arch.Because of
their porous character, lattice structures represent a distinct class of energy absorption materials that offer
versatility in changing the response to impulse loads above previous materials. Therefore, incorporating these
kinds of lattice structures into shoe footbeds would improve and increase user safety. The typical foam insoles
and shoe insoles will be replaced with a better and more appropriate lattice construction that has the best load
absorption qualities. The product's ergonomic design allows it to elastically bend in response to different foot
impressions. This prevents the possibility of physical issues like blisters and calluses on the soles of the feet by
ensuring regular pressure distribution of the body weight on the insole, which in turn reduces the concentration
of natural foot reaction.

3. Bill of Materials: -
Item Quantity Part Name Part Description Material
1 1 Shoe Insole Shoe insole with diamond Thermoplastic
lattice structure Polyurethane
TPU95A

4. Ethical Considerations: -
The material used for the product is TPU95A as mentioned in the BOM. This material is 100% biodegradable
and recyclable and therefore, beneficial in an environmental perspective.

5. Safety: -
The product is designed ergonomically to elastically deform based on the various feet impressions. This ensures
uniform pressure distribution of the body weight on the insole counterrally reducing the concentration of normal
reaction of the feet and thereby avoiding the possible occurrence of physical problems like blisters and calluses
on the feet soles.

6. Conclusions: -
The proposed design of the shoe insole addresses all the problems encountered in the use of the current insoles.
The shape of the insole is modified to suit curve-footed as well as flat-footed people. The insole is engineered
for routine use and is not specific to orthopaedic or any other medical issue. The improved design of the product
increases the overall lifetime of the product. The manufacturing of the product is also very convenient and cost-
effective. Therefore, the overall cost of the product reduces for the customer and rebuying the product would
 not be a concern. Lastly, it can be concluded by saying that the product meets all the customer and manufacturer
requirements thereby confirming the design to be a total success.

7. Acknowledgement: - We would like to thank our professor and mentor Dr. Venkatesan K for all the guidance
provided.

References: -
[1] Zolfagharian, Ali, et al. "Custom shoe sole design and modeling toward 3D printing." International Journal of
Bioprinting 7.4 (2021).
[2] Spahiu, Tatjana, et al. "Optimization of shoe sole design according to individual feet pressure maps." Computers
in Industry 125 (2021): 103375.
[3] Teixeira, Rafaela, et al. "Towards customized footwear with improved comfort." Materials 14.7 (2021): 1738.
[4] Koteswari, S., and Shivraj Narayan Yeole. "Development of 3D printed orthotic device for flat foot problem."
Materials Today: Proceedings 44 (2021): 2435-2441.
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