Method for manufacturing a customized insole and a system therefor

Abstract

Disclosed is a method for manufacturing an insole for a shoe. The method comprises providing instructions to a person to attain a first pose; capturing a first three-dimensional image of a first foot of the person in the first pose; providing instructions to the person to attain a second pose, wherein the second pose is different from the first pose; capturing a second three-dimensional image of a second foot of the person in the second pose; generating a first three-dimensional model of the first foot from the first three-dimensional image; generating a second three-dimensional model of the second foot from the second three-dimensional model; manufacturing a first insole for the first foot based on the first three-dimensional model of the first foot; and manufacturing a second insole for the second foot based on the second three-dimensional model of the second foot.

1 . A method for manufacturing an insole for a shoe, the method comprising:
 identifying a first pose of a first foot and a second foot, wherein the first pose is a first lunge pose that is configured to expose a longitudinal arch and a transverse arch of the first foot;   capturing a three-dimensional image of a bottom of the first foot in the first pose with an image capture device, the captured three-dimensional image including the longitudinal arch and the transverse arch of the first foot;   generating a three-dimensional model of the bottom of the first foot from the three-dimensional image; and   creating a first insole for the first foot based on the three-dimensional model of the bottom of the first foot.   
     
     
         2 . The method according to  claim 1 , further comprising:
 identifying a second pose of the first foot and the second foot, wherein the second pose is a second lunge pose that is configured to expose a longitudinal arch and a transverse arch of the second foot;   capturing a three dimensional image of a bottom of the second foot in the second pose with the image capturing device, the captured three-dimensional image including the longitudinal arch and the transverse arch of the second foot;   generating a three-dimensional model of the bottom of the second foot from the second three-dimensional image; and   creating a second insole for the second foot based on the three-dimensional model of the bottom of the second foot.   
     
     
         3 . The method according to  claim 2 , wherein creating the first insole and creating the second insole further comprises:
 printing a first mold having a depression corresponding to a curvature of the longitudinal arch and the transverse arch of the first foot;   printing a second mold having a protrusion corresponding to the curvature of the longitudinal arch and the transverse arch of the first foot;   printing a third mold having a depression corresponding to a curvature of the longitudinal arch and the transverse arch of the second foot; and   printing the fourth mold having a protrusion corresponding to the curvature of the longitudinal arch and the transverse arch of the second foot.   
     
     
         4 . The method according to  claim 3 , further comprising:
 aligning a first non-molded insole having a first surface and a second surface between the first mold and the second mold, such that the protrusion of the second mold is facing towards the first surface of the first non-molded insole and the depression of the first mold is facing towards the second surface of the first non-molded insole;   shaping the first non-molded insole between the first mold and the second mold to produce the first insole;   aligning a second non-molded insole having a first surface and a second surface between the third mold and the fourth mold, such that the protrusion of the fourth mold is facing towards the first surface of the second non-molded insole and the depression of the third mold is facing towards the second surface of the second non-molded insole; and   shaping the second non-molded between the third mold and the fourth model to produce the second insole.   
     
     
         5 . The method according to  claim 1 , wherein creating the first insole and the second insole further comprises:
 printing the first insole for the first foot, corresponding to the three-dimensional model of the bottom of the first foot; and   printing the second insole for the second foot, corresponding to the second three-dimensional model of the bottom of the second foot.   
     
     
         6 . The method according to  claim 1 , further comprising:
 recording a first set of data relating to a stance of the first pose of the first foot; and   recording a second set of data relating to a stance of the second pose of the second foot attained by the person based on the provided instructions.   
     
     
         7 . The method according to  claim 6 , further comprising:
 comparing the first set of data with a predefined first set of data corresponding to the first pose;   comparing the second set of data with a predefined second set of data corresponding to the second pose;   generating corrective instructions for achieving the first pose and the second pose if the first set of data and the second set of data does not match with the predefined first set of data and the predefined second set of data.   
     
     
         8 . The method according to  claim 6 , wherein the first set of data is a first weight distribution between the first foot and the second foot, and the second set of data is a second weight distribution between the second foot and the first foot. 
     
     
         9 . A system for manufacturing an insole for a shoe, the system comprising:
 an image capturing device configured to capture a first three-dimensional image of a bottom of a first foot in a first pose, the first pose configured to expose a longitudinal arch and a transverse arch of the first foot for capture by the image capture device;   a processor configured to generate a three-dimensional model of a bottom of the first foot from the three-dimensional image; and   a casting apparatus configured to create a first insole for the first foot based on the three-dimensional model of the bottom of the first foot.   
     
     
         10 . The system according to  claim 9 , further comprising:
 the image capturing device being configured to capture a three-dimensional image of a bottom of a second foot in a second pose, the second pose configured to expose a longitudinal arch and a transverse arch of the second foot for capture by the image capture device;   the processor being configured to generate a three-dimensional model of the bottom of the second foot from the three-dimensional image of the bottom of the second foot; and   the casting device being configured to create a second insole for the second foot based on the three-dimensional model of the bottom of the second foot.   
     
     
         11 . The system according to  claim 10 , further comprising a printing device communicatively coupled to the processor, the printing device being configured to:
 print a first mold having a depression corresponding to a curvature of the longitudinal arch and the transverse arch of the first foot; and   print a second mold having a protrusion corresponding to the curvature of the longitudinal arch and the transverse arch of the first foot;   
     
     
         12 . The system according to  claim 11 , wherein the casting apparatus is further configured to:
 align a first non-molded insole having a first surface and a second surface between the first mold and the second mold, such that the protrusion of the second mold is facing towards the first surface of the first non-molded insole and the depression of the first mold is facing towards the second surface of the first non-molded insole; and   shape the first non-molded insole between the first mold and the second mold to produce the first insole for the first foot.   
     
     
         13 . The system according to  claim 10 , wherein the printing device is further configured to:
 print a third mold having a depression corresponding to a curvature of the longitudinal arch and the transverse arch of the second foot; and   print a fourth mold having a protrusion corresponding to the curvature of the longitudinal arch and the transverse arch of the second foot.   
     
     
         14 . The system according to  claim 13 , wherein the casting apparatus is further configured to:
 align a second non-molded insole having a first surface and a second surface between the third mold and the fourth mold, such that the protrusion of the fourth mold is facing towards the first surface of the second non-molded insole and the depression of the third mold is facing towards the second surface of the second non-molded insole; and   shape the second non-molded insole between the third mold and the second mold to produce the second insole for the second foot.   
     
     
         15 . The system according to  claim 12 , further comprising a printing device communicatively coupled to the processor, the printing device configured to:
 print the first insole for the first foot corresponding to the three-dimensional model of the first foot; and   print the second insole for the second foot corresponding to the three-dimensional model of the second foot.   
     
     
         16 . An apparatus comprising:
 a processor;   an image capture device connected to the processor; and   a sensor coupled to the processor, the sensor configured to detect an elevation between a heel of a foot and a ground plane, wherein the processor is configured to:   determine that the foot is in a first pose;   capture an image of a sole of the foot in the first pose;   generate a three-dimensional model of the sole of the foot from the image; and   map the generated three-dimensional model of the sole to a model of an insole for creating the insole.   
     
     
         17 . The apparatus according to  claim 16 , wherein the processor is configured to determine that the foot is in the first pose by:
 comparing the detected elevation to a pre-determined elevation;   comparing a toe position of the foot to a pre-determined toe position; and   determining that the detected elevation and the toe position are within a pre-determined range of the pre-determined elevation and the pre-determined toe position.   
     
     
         18 . The apparatus according to  claim 16 , wherein the imaging capture device is configured to scan the sole of the foot in the first pose and capture contours of the sole of the foot in the first pose. 
     
     
         19 . The apparatus according to  claim 16 , further comprising a printing device, the printing device being configured to print the insole based on the model of the insole. 
     
     
         20 . The apparatus according to  claim 16 , further comprising an instructing device, the instructing device being configured to provide instructions to attain the first pose of the foot.