Kajian Reka Bentuk dan Fabrikasi Alat Rehabilitasi Kaki Ergonomik bagi Penderita Bunion Menggunakan Teknologi Pembuatan Aditif

Bunion or Hallux Valgus is a bony bump at the joint connecting the foot with the big toe. Bunions cause pain and discomfort especially when wearing shoes. Choosing appropriate footwear is not a real solution because it is limited to selecting open-toed shoes to avoid pressure on this area. Commercial insoles are generally available in standard sizes, whereas this phenomenon varies from one individual to another. Therefore, the objective of this study is to suggest bunion pads design with custom designs according to individual needs and then fabricate them using economical methods for small-scale production, i.e., additive manufacturing. A subject chosen in this study experiences bunion problems at the initial formation stage. Interview methods and anthropometric data collection on the patient’s foot using vernier calipers and an anthropometer were conducted before designing the bunion pad according to the subject’s size and foot shape. Fabrication was carried out using a 3D printing method called Fused Deposition Modeling (FDM), and the material used was Thermoplastic Polyurethane (TPU). Pressure distribution on the subject’s foot was taken without wearing the bunion pad using a Tactilus pressure mapping system to compare areas with high pressure and ensure that the design could provide comfort to the subject. The design of this bunion pad is divided into two parts, namely the thumb liner and the liner on the metatarsal (MTP) region. In the interview, after wearing the bunion pad with a 60% infill density, which was specifically designed to support pressure on the subjects, users reported improved comfort.