Design and Rapid Manufacturing of a customized foot orthosis: a first methodological study

Fantini, Massimiliano; Crescenzio, Francesca De; Brognara, Lorenzo; Baldini, Nicola

doi:10.1007/978-3-319-45781-9_46

Cited by 13 publications

(14 citation statements)

References 6 publications

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“…Given the high reliability and low SEM for most of the parameters, a direct validation of the measurements against measurements made by using medical images will be needed for future applications that required accurate data for decision-making, such as in a clinical setting. Further studies may also include more parameters based on the reconstructed weight-bearing 3D sole surface measured by the current approach, such as the distances of the first and fifth metatarsophalangeal joints to the sustentaculum tali, great toe height, distal end of the first toe and instep height [15,16,53,54], and may determine their test-retest reliabilities. One senior and one junior rater were used in the current study following previous protocols [35][36][37].…”

Section: Discussionmentioning

confidence: 99%

Test-Retest Reliability of Sole Morphology Measurements Using a Novel Single-Image-Based Pin-Array Impression Reconstruction Method

et al. 2021

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Background: Assessment of the sole morphology provides a clinically useful measure of the foot condition, but existing methods are mostly limited to two-dimensional or non-weight-bearing conditions. The current study aimed to assess the reliability of a novel method called Single-Image-Based Pin-Array Impression Reconstruction Method (SIBPAIR) implemented on a commercial foot assessment system, and the intra-rater, inter-rater and inter-session reliability of the SIBPAIR-based protocol for three-dimensional sole morphological measurements. Methods: The reliability of the SIBPAIR method, and the intra-rater, inter-rater, and inter-session reliability of the SIBPAIR-based protocol in measuring morphological parameters of the sole were assessed by repeated measurements of fifteen young healthy adults by two male physical therapists, in terms of intra-class correlation coefficients (ICC) and standard error of measurement (SEM). Results and Conclusions: The SIBPAIR method was found to have very high reliability with very small SEM values, and the SIBPAIR-based protocol also showed very high intra-rater, inter-rater, and inter-session reliability with small SEM. These results indicate that accurate and reliable measurements could be obtained by following the protocol regardless of the rater’s experience or time of measurement. This will be useful for foot assessment and subsequent applications, such as design and manufacture of customized orthoses or shoes.

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Section: Discussionmentioning

confidence: 99%

Test-Retest Reliability of Sole Morphology Measurements Using a Novel Single-Image-Based Pin-Array Impression Reconstruction Method

et al. 2021

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“…2,3,27,28 The production of a CMI that meets the biomechanical requirements for damping and support is demanding from material and mechanical points of view, knowledge, and skills. 1,[3][4][5]7,15,21,27,28 It follows from the above that a fundamental assumption for the successful designing CMIs is to understand the correlation of the foot to posture 29 and other aspects of the musculoskeletal system, 1,[3][4][5][6][7][8][9] to perceive relationships to associated diseases and cognition of the biomechanics, 1,4,5,12 weight-bearing activities 1,3,[5][6][7]9 of humans, and pathological forces 1,3,[5][6][7]13 which affect the foot. In general, the main principle in the design of CMI is the correction of deformities, 1,3,[7][8][9] reductions of painful symptoms, [3][4][5]…”

Section: Introductionmentioning

confidence: 99%

3D Printing of Individual Running Insoles – A Case Study

Danko,

Sekac,

Dzivakova

et al. 2023

ORR

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The study's starting point is to find a low-cost and best-fit solution for comfortable movement for a recreational runner with knee pain using an orthopedic device. It is a case study. The research aims to apply digitization, CAD/CAM tools, and 3D printing to create an individual 3D running insole. The objective is to incorporate flexible shape optimization would provide comfort reductions in foot plantar pressures in one subject with knee pain while running. The test hypothesis was if it is possible to make it from one material. For this purpose, we created a new digital workflow based on the Decision Tree method and analyzed pain and comfort scores during user testing of prototypes. Patient and Methods: The input data were obtained during a professional examination by a specialist doctor in the orthopedic outpatient clinic in the motion laboratory (DIERS 4D Motion Lab, Germany) with the output of data on the proband's complex movement stereotype. Surface and volumetric data were obtained in the biomedical laboratory with the 3D scanner. We modified the digital 3D foot models in 3D mesh software, developed the design in SW Gensole (Gyrobot, UK), and finally incorporated the internal structure and the surface layer of the insole data of the knowledge from the medical examination, comfort analyses, and scientific studies findings. Results: Four complete 3D-printed prototypes (n=4) with differences in density and correction elements were designed. All of them were fabricated on a 3D printer (Prusa i3 MK3S, Czech Republic) with flexible TPU material suitable for skin contact. The Participant tested each of them five times in the field during a workout and final insoles three months on the routine training. Conclusion: A novel workflow was created for designing, producing, and testing full 3D-printed insoles. The product is fit for immediate use.

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“…Most of the commercial orthoses are only partially realized with AM technologies and then assembled to constitute the final device, with a consequent increase in production phases and costs depending on the particular orthosis to be made [12]. In the literature there are different works about wrist orthoses [13], foot orthoses [14] and hip orthoses [15], but there is not much information about the customised elbow orthosis. For this reason, this work focuses on the study of an elbow orthosis.…”

Section: Introductionmentioning

confidence: 99%

A new design approach for customised medical devices realized by additive manufacturing

Ricotta

Campbell

Ingrassia

et al. 2020

Int J Interact Des Manuf

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The aim of this work is the design of a new customised elbow orthosis completely realized by Additive Manufacturing and the development of generative algorithms for parametric modelling and creation of 3D patterns to be adapted to the CAD model. This work describes a method to perfect the design of a custom elbow orthosis. A reverse engineering approach has been used to digitalize the patient’s arm and the subsequent CAD modelling of the structure of the custom elbow orthosis has been performed. In particular, two algorithms have been implemented for the creation of 3D patterns and Voronoi tessellations. Subsequently, FEM analyses have been carried out to validate the design. Finally, a prototype of the elbow orthosis with Voronoi tessellation has been realized by means of the SLS technology. The results obtained have demonstrated that the implemented algorithm solved the problems found during CAD modelling with conventional software. Furthermore, the results of FEM analyses have validated the design choices. All this allowed realizing the prototype by AM technologies without problems. Moreover, the new proposed modelling approaches allows creating, in an interactive way, patterns on complex surfaces. The results of this research activity present innovative elements of originality in the CAD modelling sector, which can contribute to solving problems related to the modelling for Additive Manufacturing. Furthermore, another innovative characteristic of the device is the use of torsion springs that simulate the action of physiotherapists during exercises for patient rehabilitation.

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Design and Rapid Manufacturing of a customized foot orthosis: a first methodological study

Cited by 13 publications

References 6 publications

Test-Retest Reliability of Sole Morphology Measurements Using a Novel Single-Image-Based Pin-Array Impression Reconstruction Method

Test-Retest Reliability of Sole Morphology Measurements Using a Novel Single-Image-Based Pin-Array Impression Reconstruction Method

3D Printing of Individual Running Insoles – A Case Study

A new design approach for customised medical devices realized by additive manufacturing

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