Development of a high-performance lattice cushioning system for shoe insoles

Abstract

All of the materials used to produce soles for traditional casual athletic shoes are nearly uniform, foam-based materials which lack any ability to regulate the long-term durability and energy absorption properties of the shoe. The recent advances of lattice-based additive manufacturing technologies have given rise to an opportunity to produce unique contoured cushioning systems that can be constructed with adjustable mechanical properties by varying the topology and porosity in a controlled manner. This research paper discusses the investigation of three types of lattice structures (i.e., gyroid, diamond, and Kelvin cell) when subjected to compressive load conditions. The lattice samples were created with four variations of porosity (i.e., 50%, 60%, 70%, and 80%) as well as two variations of thickness (i.e., 0.8 mm and 1 mm). Flexible ABS resin was produced by using the Vat photopolymerization process and the resultant samples were characterized through mechanical testing. Quasi-static loading and numerical analysis were performed on samples created using SLA technology. The results indicate that the mechanical characteristics of the three lattice types, as dictated by their topology and relative density, greatly influenced the performance of each structure; specifically, the gyroid lattice provided the best mechanical performance with the highest load resistance and the most uniform stress distribution. The diamond lattice was second to the gyroid lattice, while the Kelvin cell was found to have the lowest stiffness and failed by exhibiting signs of instability at the highest porosity levels before the other two lattice performed.

Keywords

lattice structures / TPMS lattice / gyroid / stereolithography additive manufacturing / compressive strength

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