Challenge: A Custom Solution for an Active Lifestyle
Imre Patterson, the youngest of three boys, was born with a femoral discrepancy, leaving one leg shorter than the other. Despite this challenge, he is an incredibly active child with a contagious smile and an eagerness to embrace life. His traditional foam boot, designed to compensate for the length difference, limited his movement and athletic abilities. Seeking a better solution, his family explored 3D printing technology as a way to improve his mobility and overall quality of life.
A family friend introduced them to Dinsmore Inc., a leading 3D printing and additive manufacturing provider in Orange County with over 25 years of experience. Understanding Imre’s needs, the Dinsmore team set out to create a custom 3D printed orthotic—a lightweight, durable, and adaptable midsole designed to support his active lifestyle.
Solution: Advanced 3D Printing for a Personalized Fit
Dinsmore’s team approached the project in two phases, leveraging cutting-edge 3D printing technologies and materialsto develop a more functional alternative to Imre’s foam boot.
Phase 1: HP Multi Jet Fusion (MJF) Technology
The first iteration of Imre’s orthotic was created using Nylon 12PA with HP’s Multi Jet Fusion (MJF) technology. This process selectively melted fine grains of powder using a binding agent and heat to form a durable yet lightweight latticed midsole.
- Benefit: Lighter and stronger than his traditional foam boot, enabling more freedom of movement.
- Limitations: The material was not as responsive to his level of activity, leading to further refinement.
Phase 2: Carbon’s Digital Light Synthesis™ (DLS) Technology
To enhance comfort, responsiveness, and durability, the team turned to Carbon’s Digital Light Synthesis™ (DLS) technology, the same process used to create Adidas 4D Futurecraft shoes.
- Material Upgrade: Elastomeric polyurethane, offering a more flexible and shock-absorbing midsole.
- Precision Fit: Using light to shape the liquid material into a customized lattice structure, the midsole was engineered specifically for Imre’s shoes.
- Seamless Integration: The shoes, provided by Chris Hillyer at Deckers Brands, were 3D scanned by Conner Morris at the SEMA Garage, allowing Dinsmore’s engineers to design a CAD model for a perfect fit with TEVA and UGG footwear.
Results: A Future-Proof, Scalable Orthotic Solution
The digital design of the midsoles means Imre’s orthotics can grow with him. As he gets older, the lattice structure can be modified and reprinted, eliminating the need for entirely new designs.
“As Imre grows, we can take the baseline of what we’ve already done, modify that lattice structure, and create another midsole.”
— Jay Dinsmore, CEO & Founder, Dinsmore Inc.
Jason Lopes, Production Development Engineer at Carbon, echoed this sentiment, highlighting that 3D printing allows for continuous iteration, ensuring Imre’s orthotics evolve alongside him.
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Conclusion: Empowering Mobility Through Innovation
By harnessing the power of 3D printing, Dinsmore Inc. helped turn Imre’s mobility challenges into opportunities. The lightweight, high-performance orthotics not only improved his comfort but also unlocked new possibilities for his active lifestyle.
As Imre continues to grow, Dinsmore’s additive manufacturing team will remain by his side, adapting his orthotics to meet his evolving needs. His journey is a testament to how technology, innovation, and compassion can work together to transform lives—one step at a time.
