Ankle foot orthoses (AFOs) are traditionally manufactured using vacuum thermoforming as shaping technology. Additive manufacturing has the potential to disruptively change the way these orthopaedic devices are produced. In this study, AFOs are developed which are virtually designed and produced with laser sintering as shaping technology. The mechanical and clinical performances of these laser-sintered AFOs are compared with traditionally manufactured AFO by asking seven patients (both children and adults) to walk with each type of AFO.
This study has created a screening tool to identify children likely to benefit from AFO tuning based on kinematic data and which could be used in the community.
The purpose of this study was to create and validate a standardized framework for the evaluation of the ankle stiffness of two designs of 3D printed ankle foot orthoses (AFOs). The creation of four finite element (FE) models allowed patient-specific quantification of the stiffness and stress distribution over their specific range of motion during the second rocker of the gait. Validation was performed by comparing the model outputs with the results obtained from a dedicated experimental setup, which showed an overall good agreement with a maximum relative error of 10.38% in plantarflexion and 10.66% in dorsiflexion. The combination of advanced computer modelling algorithms and 3D printing techniques clearly shows potential to further improve the manufacturing process of AFOs.
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