As interest in personalized biomechanical interventions grows, customized insoles have garnered attention for their ability to improve plantar pressure distribution and foot comfort. While previous studies primarily focused on pressure redistribution, systematic quantitative evaluations across different foot types remain limited. Notably, objective assessment methods that link plantar pressure-based structural metrics with subjective comfort are still insufficient. In this study, customized insoles were fabricated for 32 adults using plantar pressure-based foot shape acquisition and additive manufacturing, and their biomechanical effects were evaluated. The arch index (AI) and subjective comfort were measured before and after one month of use. AI was calculated from static plantar pressure data, and comfort was assessed across multiple foot regions using a visual analogue scale. Statistical analysis revealed significant improvements in comfort at the arch, ankle, and rearfoot regions (p < 0.05). The mean AI deviation from the normal reference value decreased by approximately 30.6%, indicating a shift toward a more normalized arch pattern. Overall, this study demonstrates that customized insoles can enhance plantar contact characteristics and perceived comfort across different foot types. These findings provide quantitative evidence for engineering evaluation and establish a foundation for the objective assessment of personalized insole performance.
This study presents a method for fabricating customized insoles using fused filament fabrication (FFF) and user-specific foot shape data. We evaluated the method's effects through plantar pressure distribution and Arch Index (AI) analysis. To capture plantar contours, we designed a kit-type impression-based acquisition process. The resulting impressions were digitized using three-dimensional (3D) scanning. We aligned the scanned plantar impression with a base insole CAD model, iteratively modifying and verifying the upper surface to reconstruct a customized insole geometry. The final insole model was exported in STL format and produced using FFF with a thermoplastic polyurethane (TPU) filament and a 25% honeycomb infill structure. A subject with a high arch wore the customized insoles during daily activities for one month, with plantar pressure data collected three times before and after the wear period. After using the customized insoles, the midfoot contact area increased from approximately 10–15% to 20–25% of the total plantar contact area, and the plantar load distribution shifted from a forefoot-rearfoot concentration to a more balanced pattern. These results demonstrate that the proposed FFF-based customized insole effectively enhances medial arch support and promotes a balanced plantar load distribution.