3D Printed Large-Scale Insole and its Printing Challenges

Md Hazrat Ali, Sanjar Trubayev, Essam Shehab

Research output: Chapter in Book/Report/Conference proceedingConference contribution


Additive manufacturing is a relatively new technology that is already widely applied in engineering and has a great potential to be implemented in the footwear industry. Indeed, significant improvements in the quality of 3D printed parts contribute to the quality enhancements on additive manacling in footwear industries, and the fabrication of insole is one of them. This article presents the design and development of anatomical insole and highlights its printing challenges using BFlex material applying a customized Fused Deposition Modelling (FDM) printer. The dimension of the designed insole has a length and width of 300 mm and 107 mm, respectively and it has a thickness of 15.6 mm at the heel and 5 mm at the toe. The main challenges faced during the fabrication of the desired insole are build orientation, poor adhesion of the print bed, and oscillations of the printing object at top layers. Experimental results showed that the vertical orientation of the insole, 20% infill, and support structure with 15 degrees overhang angle significantly increased the printing performance.

Original languageEnglish
Title of host publication8th Brunei International Conference on Engineering and Technology 2021
EditorsMohammad Yeakub Ali, Rama Rao Karri, Shahriar Shams, Roslynna Rosli, Ena Kartina Abdul Rahman, Ramesh Singh
PublisherAmerican Institute of Physics Inc.
ISBN (Electronic)9780735442795
Publication statusPublished - Jan 10 2023
Event8th Brunei International Conference on Engineering and Technology 2021, BICET 2021 - Bandar Seri Begawan, Brunei Darussalam
Duration: Nov 8 2021Nov 10 2021

Publication series

NameAIP Conference Proceedings
ISSN (Print)0094-243X
ISSN (Electronic)1551-7616


Conference8th Brunei International Conference on Engineering and Technology 2021, BICET 2021
Country/TerritoryBrunei Darussalam
CityBandar Seri Begawan


  • 3D printing
  • Additive manufacturing
  • Bflex
  • Infill
  • Insole

ASJC Scopus subject areas

  • General Physics and Astronomy


Dive into the research topics of '3D Printed Large-Scale Insole and its Printing Challenges'. Together they form a unique fingerprint.

Cite this