DesignHistoryFile

Departmentof
Biomedical
Engineering
WayneState
University

Team:
TaylorHeilig,
SabrinaPakula,
ShreyaPotukutchi&
BradfordPugh
Class:
BME2920
Semester/Year:
Winter2016

Project:
LowCostBiodegradableBioplasticOrthotics
UserNeedsSummary:
Affordable
Easytomake
Comfortable
Simplerecipe
Easyaccesstoingredients
Marketabletodoctors/podiatrists
Durable
Waterinsoluble

GoalsandObjectives:
Orthoticduration2yearswithout
replacement
Cost$4
Orthoticpreparation30minutes
Comfortability(i.e.wornfor12hours)
Easyrecipe
Devicemustbewaterresistant
Weight0.45kg

DesignInputSummary:
DesignOutputSummary:
Goals:
Simplerecipeandshortinstructions
Orthoticlastsaminimumof2years
Focusonpeoplewithfootrelated
withoutreplacement
problems
Costnomorethan$4
Orthoticismadeofbiodegradable
Orthoticsshouldtakenomorethan
plasticmaterial
30minutestomake
Ingredientseasytoobtain
Mustbecomfortableforallusers~
wornfor12hoursaday
Easytounderstandrecipe
Ingredientseasytoobtain
Waterinsoluble
Shouldweighnomorethan0.45kg

Constraints:
Usedforheelandarchsupportofthe
foot
Minimizeeffectsofbackrelated
problems

Tobeinsertedasthesoleofashoe

Shouldbewornasoftenaspossible

Willbeusedasamedicalshoeinsert
(orthotic)

Userwillberesponsibleforproperly
insertingtheorthoticandutilizingitas
muchaspossible

Willtargetdoctorsandpodiatrists
Willtreatpeoplewithfootrelated
problemsintheUSA

DesignVerificationSummary:
Instructions:simpletounderstand
Comfort:lightweightandflexible
OrthicLifespan(goal:6weeks):
Pending
Orthoticisfasttomake(<=30
minutes):30minutestomake10
hourstocure
Waterresistant:Yes

DesignReviewSummary:
December2015
Mightnotbepossibleforusertoeven
buya$4item/$4istoomuch
Unrealistictohaveuserreplacethe
orthoticevery6weeks
Wherewilltheorthoticandshoebe
made?
Whydoesuserhavetousethe
providedshoe?

Howwillusersbemonitoredtomake
suretheorthoticwasmadeproperly?
Willtheorthoticprovidethesame
amountofcomfortasifitwasmadein
afactory?
Howwillthisshoeandorthoticresist
steppingonsharpobjectsoruneven
surfaces?
Likelihoodoftheshoestolastayear
islow
Costofpackagingandshipping?
Is$4thecostoftheshoeorjustthe
orthoticingredients?
Howmuchwouldtheingredientscost
aloneafterthefirstorthoticis
created?

Aretherespecificback/footproblems
thataretryingtobetreated?

DesignChangeSummary:
PlansforFutureDevelopments:
February2016:
Testing
Nolongertargetinglesswealthy
Fatigue,endurance,etc
populationofOrissa,India
Providesheelandarch
Targetingdoctorsandpodiatrists
support
Usedtotreatpeoplewithfoot
Minimizesbackproblems
ailmentsanddiabetesintheUSA
Ifdesigndoesnotmeetall
Theentireshoepartoftheprojecthas
requirements,aredesignand
beenscrapped
necessarytestingwillbeimplemented
Nolongerusingatraytomakethe
Createmoldinstructions
orthotic
Determinedifferentamountsof
Amoldoftheuser'sfootwillbeused
materialsforvaryingsizefeet
tomaketheorthotic

TableofContents

Background...........3
UserNeeds......3
DesignInput....4
Goals............4
Constraints........4
DesignDevelopment....5
ConceptMap........5
MorphMatrix.........5
PughMatrix...7
DesignReview......9
DesignOutput.....11
DesignVerification.....16
DesignValidation.......19
FutureWorks...21
Bibliography....23

Background
Inthe2014,UnitedStatesconsumersspent400milliondollarsonorthotics.Theactual
costofmakinganorthoticisabout$78buttheconsumerendsuppayingeighttimes
thatamount[30].ThisisverycostlyespeciallyforlowandmiddleclassAmericans.
Sincethepriceofthesemedicalgradeorthoticsaresohigh,manyAmericanscannot
affordtobefittedfororthoticsandthusmaysufferfromvariousfootailmentssuchas
plantarfasciitis

bursitistendonitisdiabeticfootulcersankle,arch,metatarsalandheel
painetc
.
Peoplewithanyofthesefootailmentscouldbenefitfromhavingorthotics.
Also,peoplewhosufferfromdiabetescouldbenefitfromorthoticssincethesepeople
oftenhaveissueswiththeirfeet.Orthoticscanhelprelievebyprovidingheelandarch
support.Currentorthoticsaddtoenvironmentalpollutioncausingmanyharmfuleffects
totheenvironment.[31].Onceamedicalgradeorthotichasbeenusedforawhile,or
hasbecomewarped,theorthoticwillgotothedumpandwillnotdegradewhichisbad
fortheenvironment.Alowcost,environmentallyfriendlyorthoticisneededsothatmore
Americancaneasetheirfootrelatedproblems.

UserNeeds
Theuserneedsweredefinedafterassessingtheamountofpeoplesufferingfromfoot
ailmentsanddiabetesandthehighcostoforthotics.

Affordable
Easytomake
Comfortable
Simplerecipe
Easyaccesstoingredients
Marketableto
doctors/podiatrists
Durable
Waterresistant

ThisorthoticisdesignedforpeopleintheUnitedStateswhocantaffordtheexpensive
medicalgradeorthoticsorwantacheaperoptionforanorthotic.Itmusthavea
moderatelylowcostbutitalsomustbecomfortablesoitdoesntcauseanyfootpain.
Peoplewillbeusingthisorthoticformanyhourseveryday,soitmustbedurable.Only
doctorsorpodiatristswillbetargetedforthisorthotickit,sotheuserdoesnthaveto
worryaboutcorrectlyfittingtheirfeettotheorthotic.Thedoctororpodiatristwillmake
themoldsofthepatient'sfeetandwillthenusethemoldstoformtheorthoticwiththe
3

givenrecipe.Ideally,thepodiatristordoctormakingtheorthoticwillhaveeasyaccess
tothematerialsthatareusedtomaketheorthotic.Thiswillensurethattheorthotics
canbeablemadeconveniently.Theorthoticwillalsobewaterresistanttoavoidwater
orsweatdamage,makingitlastlonger.Therewillbeeasytounderstandrecipesothat
thedoctororpodiatristwillhavenoissuemakingtheorthotics,anditwillnottakethem
alotoftimetomake.

DesignInput

Goals

Orthoticlastsaminimumof2yearswithoutreplacement
Costnomorethan$4
Orthoticsshouldtakenomorethan30minutestomake
Mustbecomfortableforallusers~wornfor12hours
Easytounderstandrecipe
Ingredientseasytoobtain
Waterinsoluble
Shouldweighnomorethan0.45kg

Constraints

Usedforheelandarchsupportofthefoot
Minimizeeffectsofbackrelatedproblems
Tobeinsertedasthesoleofashoe
Orthoticmustbeutilizedasoftenaspossible
Willbeusedasamedicalshoeinsert(orthotic)
Userwillberesponsibleforproperlyinsertingtheorthoticandutilizingitasmuch
aspossible
Willtargetdoctorsandpodiatrists
UsedtotreatpeoplewithfootrelatedproblemsintheUSA

Asforgoals,theorthoticsshouldlastatleasttwoyearsormorewithoutbeingreplaced,
therebyreducingthereplacementfrequencyasmuchaspossible.Thecostoftheentire
deviceshouldnotexceedfourUSdollars,asmanyoftheuserscannotaffordtopaythe
currentamountortheywishtopaylessthantheyarecurrentlypaying.Theorthotics
shouldtakeabout30minutestoconstructandallowedtenhoursofcuringtime.They
willbemadewithnaturalingredientsalongwithcommonhouseholditems.Inaneffort
toreducecostandmaketheorthoticcreationprocessfeasible,itisvitalthatthe
ingredientsbeeasilyaccessible.Theorthoticshouldbewaterinsoluble.Thisisto
avoidanypossiblewaterdamage,warpage,swellingordisintegrationoftheorthotic.
4

Becausetheuserwillutilizetheorthoticsfora(general)minimumoftwelvehoursper
day(includeswalkingandstandingtime),theorthoticsshouldbecomfortableinterms
ofdurationofuse.Lastly,theorthoticshouldhaveaweightof0.45kgorless,
preventingtheuserfromfeelingboggeddownbyaheavyshoe.

Withregardtotheconstraints,thisdesignwilltargetthedoctorsand/orpodiatristsofthe
usersintheUnitedStateswherebyitwillactasamedicalshoeinsert.Thedoctoror
podiatristwillberesponsibleforfittingtheorthotictotheusersfeet.Theorthoticswill
provideheelandarchsupportfortheuser.Inthisway,theorthoticswillbemoldedto
theusersfoottherebyprovidingsufficientsupportfortheusersfeetandinturn
minimizingtheeffectsofearlyfootandbackrelatedproblems.Theorthoticwillactas
aninsertfortheusersshoeandwill(hence)coverthesoleoftheinteriorinaparallel
andhorizontalfashion.Fortheorthotictoproperlyprovideitsmaximumeffects,they
mustbewornbytheuserasoftenaspossible.Althoughtheorthoticmaterial,
measuringtoolsandrecipewillbeprovided,thedoctororpodiatristwillberesponsible
fortheproperconstructionofthemoldandorthotic.Fortheorthotictoreachits
maximumeffect,itisvitalthattheprovidedinstructionsarefolloweddirectlytoensure
properuse.

DesignDevelopment
ConceptMap

Tobegindrawingupadesign,manydifferentideaswerebrainstormed.First,
ideaswereorientedaroundtheorthoticinsert.Subcategoriessuchastheoptionof
creatingshoes,thetargetmarket,whetherornottomakeakit,materialsoftheorthotic,
andtypesofinstructionswerecreated.Duringthetimeofthecreationoftheconcept
map,itwasunknownwhetherornotashoewouldbeincludedwiththeorthotic.Allof
thepossibleideaswereputintoaconceptmapasshowninFigure1.Thefirstdesign
includedashoe,however,thecurrentdesignonlyfocusesontheorthoticandwillnot
includeashoe.SincemostpeopleownshoesintheUnitedStates,itisunnecessaryto
includeshoesintotheproject,soallpartsoftheconceptmaprelatedtotheshoecanbe
ignored.ThischangewasmadeinFebruary,2016.

Figure1:ConceptMap

MorphMatrix

Fromtheconceptmap,sixmaincategorieswerechosentofocusthedesign
around.Itwasdecidedthatashoeandanorthoticwastobeincludedinthedesign.
Thesesixcategorieswereincludedbecausetheydealtwiththedesignanddurabilityof
theshoe,thecreationoftheorthoticandtheinstructionsfortheusers.Multipleoptions
werechosenfromthetheconceptmapforeachcategory.Theseoptionsaredisplayed
inTable1.Next,severaldifferentdesignoptionswerechosenfromthetablebelow.
Theseoptionsinclude:

Option1:
soybeanoil,pictorialinstructions,drawstringtie,EVA,coloredmeasuringtools

thatcoordinatewithingredients,givetraytomakeorthoticandsupplyshoe
Option2:

Soybean,Pictorial,Zipper,Grass/hey,Gelatin,Numbers,UsersTools
Option3:

Waterrepellent,Multilanguage,Velcro,Hemp,Gelatin,ColourDiagrams/
ColouredInstructions/GivenTools
Option4:

HydrophobicMaterial,Pictorial,Velcro,Leaves,ElasticPadding,Wordwith
Pictures,UserTools
6


Option5:

SoybeanOil,ShortSentences,buckles,Newspaper,Gelatin,JustPictures,

GivenTools
Option6:

WaterRepellentSpray,MultipleLanguages,Laces,Grass/Gay,Elastic
Padding,WordswithPictures,PartiallyGivenToolsandUsersHouseholdItems

AllsixoftheseoptionswerecomparedusingthePughmatrixtoseewhichoptionmet
therequirementsthebest.However,sincetheshoeisnolongerpartofthedesign,the
whitepartsinTable1canbeoverlooked.

Table1:MorphMatrix

Option1

Option2

WaterRepellent

Wax

Instructionseasy
tounderstand

Option3

Option4

Option5

Option
6

SoybeanOil Water
repellent
spray

Hydrophobic
material

Pictorial
instructions

Multiple
Languages

Short
Sentences

Shoetofoot
adherence

Laces
(given)

Zipper

Velcro

Buckles

Drawstring
Tie

Laces
(hemp)

Comfort/Support
TopofOrthotic

Newspaper

Cotton

Memory
Foam

Grass/Hay

EVA

Leaves

Methodof
Measuring

Numbers

Color
diagrams/
Colored
instruments

Colored
toolsthat
coordinate
with
ingredients

Justpictures

Worded
instructions

Word
with
pictures

UserMethodof
OrthoticCreation

Supplied
orthotic
(shoeand
orthotic)

Notools
supplied

Partially
giventools
andusers
household
items

Givetrayto
makeorthotic
andsupply
shoe

Traythat
stayswith
orthoticto
putinshoe
andtools

PughMatrix
Afterthemorphmatrixwascreated,thesixdifferentoptionswereevaluatedinTable2
toseewhichoneoptionbestmettherequirements.Acurrentshoe/orthoticwasusedas
thebaseline.Ascoreforeachcategorywasgiventoeachoptiontodeterminehow
7

importanteachcategoryistothedesign.Allthedifferentoptionswerethenevaluated.If
anoptionreceiveda1asascore,itperformedbetterinthatcategorythanthebaseline
iftheoptionwasgivena1thenitperformedworsethanthebaseline,anda0meansit
performedthesameasthebaseline.Theoptionwiththehighestscoremetthe
requirementsthebest.Mostoftherequirementswererankedveryhighbecausethey
wereveryimportantforthedesignoftheshoeandorthotictobesuccessful.The
requirementfortheproducttobeeasilydistributedwasgivenalowernumberjust
becausetherearemanydifferentwaystoshipapackageanditissomethingthatwillbe
lookedintomorelateron.Theshoebeingaestheticallyappealinghasamuchlower
scorethananyoftheotherrequirementsbecauseitismoreimportantfortheshoetobe
functional,although,itispreferredthattheshoeisaestheticallyappealing.Ultimately,
option1waschosenasthemostpracticaloptionsinceithadthehighestscoreonthe
pughmatrix.Again,thewhitepartsofthetablecanbeignorednowthattheshoeisno
longerpartoftheproject.

Table2.PughMatrix
ORTHOTIC

Requirement Weigh Baseline

Option Option Option Option
s
t
Option1 2
3
4
5
Option6
Supportbody
weight
distribution
equally

0 TBD*

TBD*

TBD*

TBD*

TBD*

TBD*

Providesarch
andback
support

10

0 TBD*

TBD*

TBD*

TBD*

TBD*

TBD*

Easy
instructions

10

Aesthetically
appealing

Useslocal
resources

Comfortable

Easyto
distribute

EasyProcess

0 TBD**

RankScore

30
8

TBD**

TBD**

TBD**

TBD**

TBD**

14

12

14

10

DesignReview
December2015
Thisfirstreviewwasperformedontheorthoticandshoedesigns.Thepartsreferringto
theshoearenolongerrelevant.
SummaryofFeedback:
Mightnotbepossibleforusertoevenbuya$4item/$4istoomuch
Oddtohavetoreplacetheorthoticevery6weeks
Wherewilltheorthoticandshoebemade?
Whydoesuserhavetousetheprovidedshoe?
Howwillusersbemonitoredtomakesuretheorthoticwasmadeproperly?
Willtheorthoticprovidethesameamountofcomfortasifitwasmadeina
factory?
Howwillthisshoeandorthoticresiststeppingonsharpobjectsoruneven
surfaces?
Likelihoodoftheshoeslastayearislow
Costofpackagingandshipping?
Is$4thecostoftheshoeorjusttheorthoticingredients?
Howmuchwouldtheingredientscostaloneafterthefirstorthoticiscreated?
Aretherespecificback/footproblemsthataretryingtobetreated?

Strengths:
Useslocalmaterials
Simpleprocesstomakeorthotic
Usercanrepairshoeandmakestheorthotic
Decentcostbutmayneedtobelowered
Waterrepellent

Weaknesses:
Lifespanofshoe
Lifespanoforthotic
Potentialforusertomakeorthoticincorrectly
Shoeistooheavy

Thecostofthepairofshoestotalstoabout$4.12.Thisdoesnotincludethecost
oftheorthoticmaterialtheorthoticiscurrentlyunknownsincedifferentrecipesand
differentamountsofingredientsarerequiredtomaketheorthoticandwillbetestedin
thefuturetoseewhichcombinationgivethebestresult.Thecostofshippingand
9

packaginghasnotbeenlookedinto.Peoplethatmakeminimumwage,whichon
averageis$3.43/day,shouldbeabletoaffordtheshoesandorthoticmaterials.The
orthoticmaterialswillbetestedtoseeiftheycanlastlongerthan6weeks.Iftheorthotic
makesitthroughthe6weekmarkordoesntmeetthe6weekrequirement,thenthe
otherorthoticmaterialsmightbelookedintotoseeifadifferentcombinationcanlast
longerthan6weeks.Thereasonwhyshoesareprovidedisbecauseitisnot
guaranteedthatthepeopleinOrissawillhaveshoes.Providingthemwithshoeswill
ensurethattheycanusetheorthoticsproperlyandtheywillhaveabrandnewpairof
shoes.Also,sincetheshoeismadefromlocalresourcestheshoeshouldlastmore
thanayearbecausecomponentsshouldbeeasilyfixedorreplaced.Since,noone
(physicianetc.)willbearoundtoensuretheuserswillmaketheorthoticproperly,
pictorialinstructionswillbecreatedtoguidetheuserstocreatingtheperfectorthotic.It
willhavetobetestedtoseeifitprovidesthesameamountofcomfortthatafactory
madeorthoticwillprovide.Additionally,alayerofEVAwillgoovertheorthotictohelp
withcomfort,thesoleoftheshoewillbemadefromrecycledtiresandtherubber
materialwillhelpresistanysharpobjectsorunevensurfaces.

DesignChanges:

December2015:
Afterthedesignreview,nodesignchangeshaveactuallybeenmade.Testingofour
materialswilloccurbeforeanychangesaredecidedon.Anew,lightermaterialforthe
soleoftheshoewillbeconsidered,alongwithdifferentorthoticmaterialsifthecurrent
materialsdonotholduptothelifespanof6weeks.

February2016:
TheprojectisnolongertargetinglesswealthypopulationofOrissa,India.Originallythis
projectwasdesignedforacompetitiontohelppeopleindevelopingcountries,butthe
projectwasdeniedbecauseitwasnotdesignedtohelpseverelytheincapacitatedlike
thecompetitionwanted.Nowtheprojectistargetingpeoplewithfootailmentsand
diabetesintheUnitedStates.Theentireshoepartoftheprojecthasbeenscrapped
sincemostpeopleintheU.S.ownshoes.Also,atraywillnolongerbeusedtocreate
theorthotic.Aplastermoldwillbemadeoftheuser'sfoot,whichwillbeusedtoform
theorthotic.Sincethenewtargetaudienceisdoctorsandpodiatrists,theywillbeable
tomakethemoldandtheorthoticfortheirpatients.Manypodiatristsalreadydoa
similarprocessfortheirorthotics,exceptthemixturefortheorthoticwillbedifferentthan
theircurrentrecipe.Besidesthetargetaudiencebeingchangedandremovingtheshoe
fromtheproject,notmuchelsehaschanged.Also,Pictorialinstructionsarenolonger
10

neededsinceliteratedoctorsandpodiatristswillbecreatingtheorthotic,soinsteada
simplerecipeandinstructionsforthemoldwillbewritten.

DesignOutput

Simplerecipeandshortinstructions
Focusonpeoplewithfootrelatedproblems
Orthoticismadeofbiodegradable,bioplasticmaterial
Targetingdoctorsandpodiatrists

ThefocusofthisorthotickitwillbeintheU.S.,wheremanypeoplesufferfootailments
anddiabetes.Thekitwilltargetdoctorsandpodiatristssotheycanprovidetheir
patientswithacheaperoptionfororthotics.Asimplerecipeandinstructionswillbe
availabletothedoctorsandpodiatrists,enablingthemtoproperlyconstructorthoticof
whichismadeofabiodegradableplasticmaterialandthemold.Theinstructionswill
alsoshowtheuserhowtoplacetheorthoticproperlyintheshoe.Figure2and3display
theoriginaldesignthatincludedtheshoeandthetray.Figure4displaysthenewest
versionoftheorthotickit.Itincludesingredientbags,aqueousdroppers,andmeasuring
cups.Italsoincludesarolledupversionoftheorthotictraywhichisnolongerneeded.
However,itcanbereplacedwiththeplasterrollstomakethemoldsoftheusersfeet.

Figure2:OrthoticTray

11


Figure3:DifferingViewsoftheShoe

Figure4:OrthoticKit

12

ProcessofMakingtheOrthotic
Thepodiatristordoctorwillbeprovidedwithasimplerecipeandinstructions.The
pictureswilldesignatecoloredinstruments.Thesecoloredinstrumentswillbespecially
preparedtohold1servingofaparticularingredient,wheretheservingsizesshould
varyamonginstruments.Thecoloredinstrumentswillalsocorrelatetotheirdesignated
ingredientviaidenticalcolor.

First,thedoctororpodiatristwillmakeamoldoftheusersfootviatheprovided
plasterrollsinthekit.SubmergetheplasterrollinwaterasshowninFigure5.Then
smooththeplasterrollontotherelaxedfootlikeinFigure6and7.Twoormoreplaster
rollsmaybeneededtocovertheentirefoot.Lettheplastermoldsdryforapproximately
10minutes,remove,andthenletthemoldfinishdryingcompletely.Thefinalproduct
shouldlooklikeFigure8.Thisprocesswillbeneedtoberepeatedagain.Thissecond
setofmoldswillbeusedtocreatea3Dmodeloftheusersfeet.Withoneofthesetof
molds,sprayitwillschellack,andoncedrysprayanotherlayer,Oncetheschellackis
dry,pouramixtureofplasterofparisintothemolds,letdry,thenpeelthemoldofthe
plasterofparis.The3DmoldisdisplayedinFigure9.

Figure5:Wettingplasterclothinwater

Figure6:Moldingplasterclothtofoot

13


Figure7:Formingplastermold

Figure8:Plastermold

Figure9:3Dmoldoffeet

Tomaketheorthotic,thepodiatristordoctorwilluseapredeterminedservingof
eachingredient.Allingredientswillbecombinedintoapotorbeaker.Thepotwillbe
heated,likeinFigure10,enoughtobringtheingredientstoasimmer,whilebeing
stirredconstantly.Oncesimmering,themixturewillbeallowedtocoolslightly.Oncethe
mixtureiscoolenough(andpresumablyinagellikeform),theuserwillspreadthe
orthoticmaterialalongthemoldcoveredinplasticwraplikeinFigure11.Next,the3D
mold,wrappedinplasticwrap,willbegentlyplacedontopoftheorthoticmaterialas
showninFigure12.Thiswillpreventshrinkageoftheorthotic.Thematerialshouldbe
allowedtosetforanallottedtimeperiod.The3Dmoldcanberemovedeveryoncein
awhileforaperiodoftimetoallowairtoreachthecenteroftheorthotic.Theorthotics
canbeairedoutlikeinFigure13and14.Oncethematerialishard,itwillberemoved
fromthemoldandcoatedwithasoybeanepoxyinordertomakeitwaterproof.The
14

epoxywillneedtobealloweddryingtime,alsoforanallottedtimeperiod.Once
completelydry,theorthoticwillbeplacedbackintoitsmoldcreatingaunit.Thisunitwill
beplacedinsidetheshoeprovidedwhichcanbewornregularlyThefinalproduct
shouldlooksomethinglikeFigure15.

Figure10:Mixingofingredients

Figure11:Ingredientsspreadonmold

Figure12:Compression

Figure13:Dryingthetopoftheorthotics

Figure14:Dryingthebottomoftheorthotics

15


Figure15:Finalproduct

DesignVerification

Todetermineifourdesignoutputsmeettherequirementsofthedesigninputs
thefollowingtablewascreated.Ithasbeenconfirmedthatthedesignoutputsforthe
weightandcostoftheshoehavefailedinfulfillingthedesigninputs.Thecostofthe
shoesare$0.12overbudgetandthatisnotincludingtheorthoticmaterials.Theweight
oftheshoesisaboutdoublethetargetweightstatedinthedesigninputs.Other
materialswillhavetobelookedintotoresolvethis.Thecostfortheorthoticmaterials
hasnotbeencalculatedsinceitisnotknownatthistimehowmuchofeachmaterialwill
beneeded.Alltherestofthedesigninputsarefulfilledbytheirdesignateddesign
outputs.Tocalculatethecostandweightoftheshoes,anapproximationofhowmuch
ofeachmaterialneededwasmade.Fromthere,thecostandweightofeachwere
calculatedusingthenumbersintheverificationresultscolumn.Oncethecostofeach
componentwerecalculated,theywerealladdedtocometoasumofjustover$4.The
samewasdonewithalltheweightscomingtoatotalofabout1kg.

Again,sincetheshoeisnolongerpartoftheprojectallinformationreferringtotheshoe
canbeignored.

Table3.VerificationMatrix
DesignInput

DesignOutput

Shouldweighnomore
than0.45kg

Materialsused:
Rubber:1.522gramper
Rubber,jute,cottonlacing, (cubiccentimeter[1]
elasticmesh,toggle,EVA Jute:14strandsby15
strandsinoneinchis16oz
[2]
Cottonlacing:1.79e5kgper
1ft[3]
16

VerificationResult

Elasticmesh:[4]
Toggle:2grams[5]
3
EVA:23lb/ft
or3.2e5
3
4.81e5kg/cm
[6]
Total:1.022kg
Instructionsmustbe
universally
understandable

Pictorialinstructionswith
numbers

Comfortableforallusers
~wornfor12hours

CoverorthoticwithanEVA lightweight,goodelasticity,
padding
goodflexibility[8]

Costnomorethan$4

Materialsused:
Jute,cornstarch,water,
cookingoil,cottonlacing,
elasticmesh,toggle,EVA

Orthoticlastsaminimum
of6weekswithout

Pictogramsenhanced
comprehension[7]

Shoe:
Jute:$0.5$8/piece[9]
Rubber:disposabletires
[10]
Cottonlacing:$3.99per475
ft.[3]
Elasticmesh:$6.95peryard
[11]
Toggle:$7.52per50[12]
EVA:$0.029$0.39per
20cmx30cmpiece[13]
Total:$4.12/pairofshoes
Orthotic:
Jure(asreinforcement):
$0.50$8.0014[2]
Wheatstarch:$6.75for16
oz.[15]
Vegetableoil:$4.59per64
oz.[16]
Glycerin$12.50per500mL
[17]
Sorbitol:$10.66per473mL
[18]

Materialsusedfororthotic: Mostexistinginternational
Wheatstarch
standardsrequire
17

replacement

TbspWater
VegetableOil
Glycerin
Sorbitol

Shoelastsaminimumof
1year

biodegradationof60%
within180daysalongwith
certainothercriteriaforthe
resinorproducttobecalled
compostable.[19]

Materialused:
Rubber:takes5080years
Rubber,jute,cottonlacing, todecompose[20]
elasticmesh,toggle,EVA Jute:12yearsto
decomposeincompost[21]
Cottonlacing:15monthsto
decomposeincompost[22]
Elasticmesh:3040yearsto
decomposeincompost[22]
Toggle:70450yearsto
decomposeincompost[22]
EVA:[4]

Orthoticdoesnttakelong Liststeps:createmixture,
tomake(lessthan30
heatmixtureandallowto
minutes)
coolslightly,pourinmold,
insertfootintomixture,
allowtosetfor10hours,
placeinshoe

Orthotictakes
approximately30minto
createandmoldand10
hourstocure
[23]

Materialsneededfor
orthotic/shoemustbe
readilyavailable

Materialsused:
Jute,soybeanoil

Orissaisthe5thtop
producingstateinIndiafor
Jute[24]
Soybeanisoneofthemain
cropscultivatedinOrissa
[25]

Shoealongwithorthotic
mustbewaterinsoluble

Soybeanoil

Oilishydrophobic[26]

Willtargetthe
lesswealthypopulation
ofIndia

TargetingOrissa,India

32.59%ofpeoplebelowthe
povertyline[27]

18

Usedforheelandarch
supportofthefoot

Orthotic

absorbshock,improve
balance,andtakepressure
offsorespots[28]

Minimizeeffectsofback
relatedproblems

Orthotic

chroniclowback
pain...improvedwiththeuse
offootorthoticsaftersix
weeks.immediatebenefit
fromtheuseoffoot
orthotics[29]

BelowinTable4isalistofmaterialsusedtomaketheorthotic,howmuchisneededof
eachingredient,thetotalcostofingredient,andthetotalcostoftheentirepairof
orthotics.Wefiguredoutthecostofeachingredientbyfiguringoutthebasepriceof
eachingredientperunituse,andthenmultiplyingthatnumberbythetotalnumberof
unitsneeded.Forexample,weneeded6tablespoonsofcornstarchweweighed1
tablespoonofcornstarchandthenfiguredouthowmanytablespoonswereinthebox
sincetheboxtellshowmanygramstotalthereis.Wethenfiguredouthowmucheach
tablespooncost,andthenmultipliedthatnumberby6sinceweneeded6tablespoons
totalforthepairoforthotics.Asimilarprocesswasdonefortherestofthematerials.
Thetotalcostofeachmaterialwasaddedup,andendedupbeingjustunderourgoalof
$4.

Table4:Priceperpairoforthotics

DesignValidation
Teststhatwillbeperformedontheorthoticmaterialinclude
TensileTest
19

 3PointBendingTest
WaterAbsorptionTest

Forthetensiletest,theASTMStandardTensileTestingSpecimenShape:Dumbbell
orDogbonewasused.Theorthoticmaterialwasshapedinthisway(Figure16and
17)forthebestresults.TheMark10devicewasusedtodothetensiletesting.The
orthoticpiecewasclampedverticallyoneithersideasshowninFigure18.Theorthotic
materialwaspulledapartataspeedof35mm/minuntilitbroke.Thestressstraincurve
wasgeneratedonMATLAB.Theslopeofthelinearportionofthestressstraincurve
wasusedtocalculatethemodulusofelasticity.Thisprocesswasrepeatedfor3other
trials.TheelasticityvaluesaredisplayedinTable5.

Figure16:ASTMStandardTensileTestingSpecimenShape

Figure17:ASTMStandardTensileTestingSpecimenShape

20

Figure18:TensileTest

Table5:ModulusofElasticityofOrthotic

Figure19:Orthoticpulledapart

Trial

ModulusofElasticity

4.631GPa

23.62MPa

47.43MPa

58.35MPa

The3pointbendingtestwillbeperformedinthefuturetodeterminehowmuchloadthe
orthoticcanwithstand.Thiswillhelpusdeterminehowmuchforceapersonwillbeable
toputontheorthotic.Next,thewaterabsorptiontestwillbeperformedtoensurethat
theorthoticwillnotabsorbwater.Iftheorthoticabsorbswater,itcouldwarpovertime
andcouldcausetheusersomediscomfort.

FutureWorks
Testing
Fatigue,endurance,etc
Providesheelandarchsupport
Minimizesbackproblems
Ifdesigndoesnotmeetallrequirements,aredesignandnecessarytestingwill
beimplemented
Createmoldinstructions
21

 Determinedifferentamountsofmaterialsforvaryingsizefeet

Inthefuture,itwasplannedtodomoretestingontheorthoticenduranceandhowitwill
actuallyeffecttheuser.Anabsorptiontestwillbeperformedtoseehowwelltheorthotic
materialresistsabsorbingwater.Afinalcopyofthemoldinginstructionswillbemade.
Also,itwillbedeterminedhowmuchofeachingredientisneededforvaryingfeetsizes
toreduceanyexcesswasteofmaterials.

22

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