Mechanical Engineering, University of Michigan, Ann Arbor, MI, USA.
University of Michigan, Orthotics and Prosthetics Center, Ann Arbor, MI, USA.
Prosthet Orthot Int. 2022 Feb 1;46(1):37-41. doi: 10.1097/PXR.0000000000000071.
3D-printing is a potential manufacturing process for optimizing the design and manufacture of ankle foot orthosis (AFOs). The feasibility of an AFO with interchangeable strut that is suitable for 3D-printing is created and evaluated.
A segmented AFO with 3D-printed custom footplate and calf shell connected by a custom-made strut is studied.
The duration of a healthy subject wearing the 3D-printed segmented AFO in daily activities is used to evaluate the feasibility and durability to integrate 3D-printed AFOs into orthotics practice.
The 3D-scanning of a patient's leg is first conducted. The scanned 3D surface is modified by creating the clearance around bony prominences and trimlines for the footplate and calf shell. The footplate has a custom-shaped inside to match with the foot and a standard shape outside at the top to match and connect with the strut. For the calf shell, the inside shape is custom fit with the shank and the outside shape is standard to connect with the strut. Material extrusion is the 3D-printing process selected. Tree-like support structures are used to avoid the use of soluble support material and to eliminate the risk of residual chemical solvent in the orthosis.
The segmented AFO with material extrusion footplate and calf shell was tested in a healthy subject with an active lifestyle, offering comfort, and stability for over 4 months without breakage.
This segmented AFO is durable, requires short 3D-printing time, and enables the quick adjustment of bending stiffness via an interchangeable strut design.
3D 打印是一种优化足踝矫形器（AFO）设计和制造的潜在制造工艺。本文创建并评估了一种具有可互换支柱的 AFO 的可行性，该支柱适合 3D 打印。
研究一种带有 3D 打印定制足板和小腿壳的分段式 AFO，通过定制支柱连接。
使用健康受试者在日常活动中佩戴 3D 打印分段 AFO 的时间来评估将 3D 打印 AFO 整合到矫形实践中的可行性和耐用性。
首先对患者腿部进行 3D 扫描。通过在足板和小腿壳周围创建用于骨骼突起和修剪线的间隙来修改扫描的 3D 表面。足板具有定制的内部形状以匹配脚部，外部形状为标准形状以匹配和连接支柱。对于小腿壳，内部形状与小腿贴合，外部形状为标准形状以与支柱连接。选择材料挤出作为 3D 打印工艺。使用树状支撑结构来避免使用可溶性支撑材料，并消除矫形器中残留化学溶剂的风险。
具有材料挤出足板和小腿壳的分段 AFO 在一位生活方式积极的健康受试者中进行了测试，提供了 4 个多月的舒适和稳定性，没有出现断裂。
这种分段式 AFO 耐用、3D 打印时间短，并通过可互换支柱设计实现弯曲刚度的快速调整。
