2025 · Harvard University

AirSole

Fabrication · Huamn Factors Engineering
Parametric Design · Pneumatics

Role: Design, Fabrication, G-code Scripting, Actuation System Architecture

A pneumatically actuated footwear with customized insole fabricated in TPU, personalized to each wearer's ergonomics and gait pattern.

AirSole is a pneumatically actuated rehabilitation insole designed and fabricated at Harvard. The project begins from a clinical gap: off-the-shelf insoles cannot adapt dynamically to individual gait patterns or provide targeted therapeutic pressure during rehabilitation. AirSole addresses this through a flexible TPU lattice architecture that allows pneumatic channels to inflate dynamically to individual gait patterns and therapeutic requirements.

The design process is fully parametric, with custom G-code scripts adjust the print geometry per patient morphology, allowing each insole to be tuned to the individual's foot shape and rehabilitation protocol before fabrication. The actuation system maps pneumatic channel layout, pressure zones, and inflation sequencing to specific phases of the gait cycle.

Material

Flexible TPU FilamentLattice ArchitecturePneumatic Tubing

Fabrication

FDM 3D PrintingCustom G-code ScriptingParametric Geometry

Actuation System

Pneumatic Channel LayoutPressure Zone MappingInflation Sequencing Logic

Software

Fusion 360 / RhinoCustom G-code ScriptsPr

Application

Gait RehabilitationPatient-specific Fitting

Design

Parametric Architecture & Actuation

CAD / parametric model

Parametric TPU footwear layout

Lattice Design

  • Flexible TPU lattice provides compliance under load while maintaining structural integrity for pneumatic inflation
  • Cell geometry parametrized per patient: density, wall thickness, and channel diameter vary with morphology

G-code Parametrization

  • Custom G-code scripts adjust extrusion paths and layer patterns to match individual foot geometry from scan data
  • No manual slicing edits required, parametric pipeline from scan to print-ready file

Gait Actuation Logic

  • Pneumatic pressure zones mapped to heel-strike, midstance, and toe-off phases of gait cycle
  • Inflation sequencing logic provides targeted therapeutic pressure at clinically relevant moments

Making

Fabrication Process

Process 00 Process 01 Process 02 Process 03
Process 04 Process 05 Process 06
Process 07 Process 08 Process 09

Demo

Full Demonstration

InstructorsDaniel Tish

Special Thanks toYue Yang

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