Development of customized ankle-foot-orthosis using 3D scanning and printing technologies

Around the world, customized ankle-foot-orthosis (AFO) for patients with central nervous system damage are continuously being developed. Existing customized AFOs are manufactured by considering the size of the user's feet and calves using 3D scanning and printing technologies. In this study, we propose a customized AFO that reflects the shape of the user's feet and ankles by setting anatomically based landmarks and trim lines. Design standards are established through landmarks and trim lines, and AFOs are designed. To confirm the safety of the designed AFO, specimens using ABS and PLA were fabricated, and tensile tests were conducted. At this time, each material's density difference was considered to address the economic aspect during subsequent production. The mechanical properties were obtained through the tests and applied to the AFO model through finite element analysis to confirm the behavior of dorsiflexion and plantar flexion. Finally, ABS-AFO and PLA-AFO prototypes were produced, and after production, actual subjects wore them to confirm the difference from the existing.