Compressive behavior of thermoplastic polyurethane with an active agent foaming for 3D-printed customized comfort insoles

The primary objective of this study was to investigate the compressive behavior of 3D-printed specimens made of a thermoplastic polyurethane filament, specifically colorFabb varioShore TPU, which incorporates a foaming agent. The foaming technology makes it possible to manipulate 3D prints' properties by adjusting process parameters that affect the level of expansion, such as printing temperature, printing speed or flow ratio. This capability opens new possibilities for 3D-printed personalized foot orthotics or for static comfort-oriented applications by tailoring the stiffness of the print based on the application requirements. Since infill density and infill pattern also affect the compressive characteristics of 3D prints, this research took these two parameters into account as independent variables, alongside the printing temperature. Thus, the specimens with printing temperatures set at 190 °C, 220 °C, and 240 °C, gyroid and honeycomb patterns, and infill variations from 10 % to 35 % in 5 % increments were experimentally investigated in compression testing. The evaluation was conducted to determine the influence of these factors on the stiffness of prints at 10 % and 20 % strains, in accordance with established standard. The findings had an important practical value as they provide data for adjusting the variable stiffness based on peak plantar pressure measurement data when developing tailored foot orthoses (insoles), which was the second objective of the research. The most influential factor affecting the compressive strength was the printing temperature, followed by infill density and pattern type. The difference in compression modulus between 10 % and 20 % strains did not exhibit statistical significance. Moreover, the main effects plots indicated minimal variations in compression modulus effects at 220 °C and 240 °C, whereas an important difference was observed at 190 °C printing temperature, which was confirmed by scanning electron microscopy investigations showing foamed layers at 220 °C and unfoamed layers at 190 °C. Furthermore, interaction plots revealed no significant interaction effect among the studied variables. Additionally, a comparison of samples’ sizes and densities before and two months after testing indicated no observable modifications When applied to custom orthotics (five pairs of insoles were customized and tested), the experimental findings documented variations in the reduction and distribution of peak plantar pressure based on the infill variability.