Parametric Design,manufacturing And Performance Analysis Of Personalized Insoles Based On Multi-cameras And Line Structured Light Scanning

With the development of society and the progress of science,people in growing numbers pay more attention to all aspects of life,and put forward higher requirements for the insoles that must be used every day.When wearing the flat insoles,the stress is mainly concentrated on the forefoot and heel.So,it will increase the discomfort of a foot for a long time of wearing.But the traditional design and manufacture of personalized insoles mostly rely on pure manual methods,which leads to long manufacturing period,unreasonable design,rough manufacturing process and other shortcomings.In order to solve the above problems,this thesis proposes and realizes a complete set of solutions for the design and manufacture of personalized insoles.1).3D scanner equipment with multi-cameras and line structured light,and supporting software is developed independently.2).Parameterized automatic modeling program of personalized insoles is developed.3).The selective laser sintering(SLS)process method of personalized insoles is researched.4).And the performance of the personalized insole is analyzed.The research content and achievements of this topic are as follows:(1)The structure design for 3D scanner with multi-cameras and line structured light.Pro/E three-dimensional modeling software is used to design the structure of the three-dimensional scanner,and the U-shaped frame is the core part.In order to obtain a complete three-dimensional model of the foot,the U-shaped frame structure design was gradually optimized and finally determined.1).The orientation of the main camera lens is opposite to the left and right cameras.2).A mirror is placed in front of each camera,which angle is set to 55 degrees,and the distance from the mirror to the camera center is set to 35 mm.3).The upper part vertical plates on the left and right sides of the U-shaped frame body is bent inwardly by 10 degrees.(2)Key technologies of 3D scanner software with multi-cameras and line structured light.The software of 3D scanner is developed with C++,Qt,Open CV,Open GL and the theory of computer vision.The pairwise calibration method is used to determine the positional relationship between multiple cameras,which solves the core problem of extending from monocular to multi-purpose.And active laser triangulation and Steger algorithm with ROI is used to generate 3D point clouds,which solves the problem of slow speed to generation of 3D points in real-time.And the Poisson surface reconstruction algorithm is used to achieve 3D surface reconstruction rapidly.So,we finally obtained a complete 3D model of the foot.(3)Development of parametric automatic modeling program.A parametric automatic modeling program is developed based on the Grasshopper plug-in under the Rhino software.We only need to input the 3D foot model by 3D scanner,the thickness of insole and unit volume into the program,and the developed automatic line drawing module can draw lines and modeling automatically according to the preset parametric model.The personalized insole that matches the three-dimensional model of the foot and has a complex array structure can be modeled.The entire modeling process does not require manual intervention.This program provides a new solution for the efficient design of personalized insoles.(4)Selective laser sintering.The selective laser sintering process of additive manufacturing technology is used to produce personalized insoles.The SLS equipment is HW-S400,and the printing material is PA12 spherical powder.Experiments have proved that based on reasonable process parameters,the SLS process can print the complex array structure.And SLS provides a solution for the manufacture of personalized insoles.(5)Performance analysis of personalized insoles.ABAQUS software is used to analyze the stress situation when standing with personalized insoles,the results show that wearing personalized insoles can reduce the peak stress by about 70%.Based on the detection results of the Foot Scan equipment,the ABAQUS analysis conclusions are verified.Both analysis methods show that personalized insoles can increase the contact area between the insole and the foot significantly,and reduce the peak stress effectively.