Fabbaloo: Jon Seeks a Service
The folks over at FAbbaloo have responded to the call of Jon Kalish.
Fabbaloo reader (and freelance newspaper writer, radio reporter and podcast producer) Jon Kalish writes:
I have a pair of orthotic shoe inserts that are maybe a foot long and 4 inches wide. They are made out of a hard plastic. Do you think they can be scanned and “printed” in a softer, more rubbery plastic? … I switched health insurance companies and my new provider doesn’t cover orthotics. Podiatrist says it costs $550!
Our immediate thoughts were:
- You’d need access to a 3D scanner, 3D modeling software and 3D printer. For a one-time consumer like Jon, a service would be a far better option than purchasing
- The printer must have a fairly large build chamber, due to the size of the object and because it should be in one piece rather than assembled from multiple pieces
- The 3D printer must be able to print a “soft rubbery material”
- The print resolution would not have to be terribly precise, because the object is going to be hidden in Jon’s shoe. It just has to be smoothish
- The “soft material” would have to be fairly robust, as it’s going to be trodden upon by Jon every day
Now what? We issue a challenge to Fabbaloo readers: what is the best combination of services (scan, tweak and print) that can do the job for Jon? Is this possible to do at all (we’re wondering most about the rubbery material)? Or is it possible but not for less than US$550?
Make sure to click through to read the comments! Fabbaloo: Jon Seeks a Service.
| Tagged with | 6 comments | |
6 Comments so far
versonova
I am thinking of the polymer clay – there is a rubbery version. it is a soft clay that is moldable and the rubbery version after baked in an over to cure – it becomes the consistency of a soft pink erasure.
A syringe extruder could possibly extrude the material.
I do not have a makerbot built yet. I ordered my makerbot two days ago – in parts and not as a full kit.
Cathal
You know, I had exactly this idea on seeing my Fiancé’s orthotics; they cost a fortune to make, but with a few measurements I’m sure I can print some out on a Makerbot no trouble!
We’ll see soon.
bvac
I like rapid prototyping and personal manufacturing and all, but he could easily do this in an afternoon for under $50 by making a mold of the orthotics and casting them in dragonskin or ecoflex silicone rubber.
versonova
I feel the reason for the scanning and then extrusion is to get the correct fit of the orthotics. I would think that in and of itself fitting the orthotics is the largest reason for the $500 price tag from the professional pediatrist.
Once the first working set is made then replicating it with an extrusion system will work if the appropriate material can be syringe extruded.
But the original fitting is the difficult part.
j.pickens
The really difficult part is that whoever produces this part for the end user can’t accept payment for this work. If they take payment, they are breaking the law, as only registered medical device manufacturers may be in the business of selling orthotics.
Also, if the new comprehensive health care bills as currently proposed pass, then you’d add from 20 to 50% to the price, due to the tax on medical devices. The bill’s authors say 20%, but the actual tax is yet to be determined by “market share”, and the 50% number may be closer to the mark.
Reece Arnott
As to the 3D scanning part of it: I’m in the process of producing a java “wizard” software to help with this. The idea is to print out a known calibration sheet, place your object on it, take photos from various angles, and point the software at the images.
From there it will try and combine them into a 3D model. It’s planned to take the first year of my PhD to get the software to the point of being able ready for general use/beta testing. I am now about half way through that first year so check back in 6 months or so.
Until I have actually got working software I won’t be able to say what sort of resolution it will be able to do but I suspect the more photos you take and the more care you use in doing so, the better the 3D model.