The specification of personalised insoles using additive manufacturing André S. Salles *a and Diane E. Gyi a a Loughborough Design School, Loughborough University, Loughborough, LE11 3TU, United Kingdom Abstract. Research has been conducted to explore a process that delivers insoles for personalised footwear for the high street using additive manufacturing (AM) and to evaluate the use of such insoles in terms of discomfort. Therefore, the footwear personalisation process was first identified: (1) foot capture; (2) anthropometric measurements; (3) insole design; and (4) addi- tive manufacturing. In order to explore and evaluate this process, recreational runners were recruited. They had both feet scanned and 15 anthropometric measurements taken. Personalised insoles were designed from the scans and manufactured using AM. Participants were fitted with footwear under two experimental conditions: personalised and control, which were compared in terms of discomfort. The mean ratings for discomfort variables were generally low for both conditions and no significant differences were detected between conditions. In general, the personalisation process showed promise in terms of the scan data, although the foot capture position may not be considered ‘gold standard’. Polyamide, the material used for the insoles, demonstrated positive attributes: visual inspection revealed no signs of breaking. The footwear personalisation process described and explored in this study shows potential and can be considered a good starting point for designer and researchers. Keywords: 3D scanning, anthropometry, footwear * Corresponding author. E-mail: andre_salles@hotmail.com 1. Introduction The personalisation of footwear is potentially ad- vantageous not only for runners, but to anyone who wishes to become more active, by providing opti- mum fit, improved comfort and performance. It can also reduce injury risk through personalisation of cushioning and support requirements. Additive manufacturing (AM) technology has potential for making footwear personalisation economically feas- ible by allowing geometric freedom, its tool-less ca- pabilities and the ability to directly manufacture from CAD models [3]. However, it is not known how to specify such footwear for AM or how perso- nalisation might affect foot discomfort. Therefore, research has been conducted to explore a process that delivers insoles for personalised footwear for the high street using AM and to evaluate the use of such insoles in terms of discomfort. 2. Footwear personalisation process In order to develop a process for the design and manufacture of glove fit personalised insoles, four elements were identified:  Foot capture using a 3-D scanner;  Anthropometric measurements;  Insole design using CAD software;  Manufacture of the parts using AM technology. This process has the potential to offer footwear with optimum fit, comfort and support properties for a particular individual, but further exploration and evaluation is required. Work 41 (2012) 1771-1774 DOI: 10.3233/WOR-2012-0383-1771 IOS Press 1051-9815/12/$27.50 © 2012 – IOS Press and the authors. All rights reserved 1771