NCIIA Grant Proposal
Vanderbilt University
Team Members:
Keegan Compton -
Ryan Cook -
Michelle Lowe-
Michelle Sauer -
Advisors:
Matt Moore-
Paul King -
Administrative Contact:
Mary Judd -
Project Title: Reusable Casting Apparatus for Custom Orthotics
Abstract:
The purpose of this project is to design a reusable casting apparatus for custom orthotics which will:
· Reduce shipping costs for Sole Supports Inc.
· Maintain the casting methods used by Sole Supports Inc.
· Be environmentally friendly
Introduction:
Sole Supports Inc. is a custom orthotics manufacturing company located in Lyles, Tennessee. Currently, Sole Supports Inc. ships a foam casting box to practitioners, who take an impression of their patient's feet and then send the used foam casting box back to Sole Supports. Inc. After manufacturing the patient's custom orthotics, Sole Supports Inc. discards the used foam casting box and ships a new unused foam casting box back to the practitioner. Because Sole Supports Inc. pays for shipping to and from the practitioner, Sole Supports Inc. annual shipping costs are over $500,000. We plan to address this issue by developing a reusable casting medium, which can be scanned by use of a 3D scanner, and sent to Sole Supports via the internet. In addition to drastically reducing shipping costs, a reusable medium will also help to reduce waste and protect the environment.
History and context:
In 2006 another senior design group developed a low cost scanner and 3D imaging software that can be used in the physician's office to scan the foam cast and send the results via e-mail to Sole Supports. Their developed device led to the elimination of the need for practitioners to ship the foam back to Sole Supports, drastically cutting shipping costs. The imaging device created by the team uses a webcam and a laser. The camera is connected to a computer and to a free software program, DAVID, which creates an image of the impression that is scanned by the laser. Currently, Sole Supports rents these scanners to doctors at $10 per month. Despite this device, however, it is currently still necessary for Sole Supports to ship back new foam to the doctor each time, since the foam is not reusable. This scanner will therefore be necessary for implementing the use of the reusable casting apparatus in order to save even more on shipping costs. With both the scanner and the reusable casting apparatus, doctors will not have to ship casts back to Sole Supports, and Sole Supports will not have to send new casting material each time casting takes place.
Sole Supports has previously done their own investigation to come up with a reusable material that will fulfill the expected requirements. Currently, we are not privy to this knowledge, as Sole Supports desires that we will have a completely fresh outlook on the work. As we perform our research, Sole Supports will provide advice about materials that they have previously considered where needed.
Finally, the design team has visited Sole Supports. toured the manufacturing facility, and received instruction in Sole Supports' casting methods. Initial brainstorming and background research has been initiated.
Team:
The team consists of Keegan Compton, Ryan Cook, Michelle Lowe, and Michelle Sauer. Keegan, Ryan, and Michelle Sauer are BME seniors. Michelle Lowe is a Master of Engineering student in BME. This project has an emphasis on materials, which will be applied to designing the desired casting apparatus. In addition, a limited understanding of the foot and orthotics is necessary. All members have some background knowledge on biomaterials and anatomy through coursework. Keegan will serve as the main contact person with our outside advisor, Matt Moore, and our academic advisor, Paul King. Ryan will serve as the team's webmaster. Michelle Lowe will use her engineering management skills to help guide the project direction, and her understanding of the research process learned in graduate school to aid in the background research. Michelle Sauer will use her skills in biomechanics to provide insight into the clinical application and use of the product.
Work plan and outcomes:
Educationally, the team will gain a much better understanding and knowledge of materials. Additionally, we will gain a better understanding of the research process and the design process. Learning to work with a company and to meet their needs will be valuable experience for all team members. The main commercial outcome of this project will be to reduce the shipping costs for Sole Supports. This will be achieved by researching and testing materials that will potentially produce the desired outcome. This outcome includes an apparatus that will maintain the current method of casting used by Sole Supports, with the use of a reusable apparatus that will replace the foam. In addition, the reusable apparatus will be easily biodegraded to enhance the positive environmental impact of the altered product. At the end of the grant period, Sole Supports will be presented with the research, which will suggest the success of the tested materials for the use of their casting method. In addition, Sole Supports will be presented with a prototype of a successful casting apparatus. Therefore, at the end of the grant period, the project is expected to be complete. The project is expected to succeed because there are a wide variety of materials available that can be used to our advantage in creating the usable casting apparatus. Additionally, our team consists of four members with a variety of knowledge and skills, all of whom will bring different perspectives to the project and provide a fresh approach to the problem that Sole Supports Inc. hopes to solve.
As of today, Sole Supports spends over $500,000 on the shipping of casting foam to and from their clients. The reusable apparatus in addition to the scanning system would allow clients to digitally scan the casting images to Sole Supports, erasing a need to ship the casting box back, as well as for Sole Supports to ship back an unused casting apparatus. This would drastically reduce shipping costs: optimally through the reusable casting apparatus, the only time shipping would be necessary would be in shipping first time clients the reusable apparatus. Nevertheless, dependent upon how reusable the casting device is, it may be necessary for Sole Supports to send its clients new casting apparatuses periodically. Savings will therefore be dependent upon material costs of the new apparatus as compared to the foam, as well as the "reusability" of the apparatus (ie. how many times it can be reused by physicians before they require a new one). Finally, because Sole Supports rents the scanning systems out to physicians at $10 per month, they are able to recoup costs on the scanner via this method, and will not need to recoup these costs through decreased shipping.
Evaluation and sustainability plan:
The project will be considered a success when a device is created which:
· Preserves the original casting method
· Is reusable
· Is biodegradable
· Provides large savings for the company due to reduced shipping needs
Appendix
Budget:
Material Costs:
Research and discovery of materials will grow as the project develops. Initial estimates include:
- Mattress Material (Memory Foam Pillow) : $40
- Modeling Clay : $20
- Play-doh : $20
- Pin-art 3-D Impressions : $25
- Mud-like substances: $20 - $50
- Temperature-dependent Materials : $100*
- Memory-Shape Biomaterials : $100*
- Gels (ceramic powders and solvents) : $100*
Estimated Total: $500*
* - Price based on educated estimation. Price may change.
Travel Expenses:
- Roundtrip mileage x Standard Compensation Rate =
102 miles x $0.55/mile = $56.10
8 visits x compensation per trip ($56.10) = $448.80
Visitation + additional traveling costs ~ $500
Team Member Expertise:
Keegan Compton: I have a general interest in biomaterials, and I have taken a college course in this subject. I have also worked in the Vanderbilt University Institute of Imaging Science with MRI and blockface brain imaging which will help with the design of a material associated with scanning. I work well in teams, generate creative ideas, and possess good communication skills. I am a hard worker who is dedicated to a task when given one and makes sure it is well done.
Michelle Lowe: I have general knowledge as to the research and design processes, as well as good communication skills and leadership skills. Additionally, I have extensive experience working in teams and meeting deadlines. Finally, my prior coursework may provide insights as to how the team can successfully approach this project.
Ryan Cook: Prior coursework, such as biomaterials and bio mechanics, have given me background knowledge on topics that could be beneficial on this project. I have experience with the design process while working in the Muscle Physiology Lab at the Vanderbilt Institute of Imaging Science. Working in this lab also provided me with knowledge on muscle physiology and bio mechanics.
Michelle Sauer:I have previously worked in a motion analysis laboratory. I have assisted with clinical gait studies and preformed biomechanics research. I also have a second major in the Communications of Science and Technology.
Timeline: