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This study suggest the development of a wearable orthotic device pattern that can reduce pain and deformation, and help in the normal development of children with cerebral palsy. Such a pattern enables daily wear before hip subluxation occurs, to prevent hip dislocation and subluxation.

This study set the design line by carrying out cell work on the actual model, then proceeded with the first pattern design. The final version of the second orthotic device was designed by conducting discussions with experts and the patient's guardian, with the device fitted to the child patient. The evaluation of the second orthotic device used the virtual model to check the pressure area and level through virtual fitting. An evaluation was then conducted with the device fitted to the child patient, to verify the functionality and suitability of the final pattern.

Following the initial fitting evaluation, the second pattern was presented after modifying and supplementing issues such as movement suitability with posture change, position change of the great trochanter when wearing a diaper, pressure control of the X-shaped band on the genital area and thigh abduction. The master pattern of the final version of the second orthotic device was proposed after confirming that the femoral head of the hip joint was stably fixed, and the compression was applied through a verification based on the virtual fitting using the virtual model, and with the device fitted to the child patient.

With this study, it is expected that the process and design plan for the development of wearable orthotic device patterns for the persons with disabilities impaired mobility can be used as a basic resource to create devices that merge the clothing and medical fields.

The present field of prosthetics/orthotics is an erratic agglomerate of vague guidelines, skills and knowledge. The author conceived prosthotology to clarify, expand and enlighten prosthetics/orthotics into a science with a solid foundation and clear framework. This paper seeks to present itself as an introduction to the field and its relationship with cybernetics and systems.

Prosthotology achieves this by disregarding the established barriers between the human body, mind and environment. This traditional scheme is replaced by focusing on goals and goal systems instead. A goal system consists of a goal former and a goal achiever. When a goal achiever cannot achieve a goal, it can be amended. If a goal achiever cannot initialise, a prosthesis may provide amendment. If a goal achiever cannot propagate, an orthosis may provide amendment.

This perspective enables one to focus on a person's needs, what exactly is inhibiting these needs, and how best to permit the needs to be granted. It does not assume that, in order to achieve a goal, only the human body can be used.

Prosthotology provides direction and advancement for prosthetics and orthotics. It also enhances integration of prosthetics and orthotics with other engineering disciplines.

So far one has only scratched the surface of the potential of prosthetics and orthotics, using prosthotology, this potential is obvious and a step closer.

The purpose of this paper is to evaluate the performance of 3D printed materials for use as rapid tooling (RT) molds in low volume thermoforming processes such as in manufacturing custom prosthetics and orthotics.

3D printed specimens of different materials were produced using the Z‐Corp process. The parts were post processed using both standard and alternative methods. Material properties relevant to the 3D printed parts such as pneumatic permeability, flexural strength and wear rate were measured and compared to standard plaster compositions commonly used.

Three‐dimensional printing (3DP) can replicate the performance of the plaster materials traditionally used in prosthetic/orthotic applications by using modified post process techniques. The resulting 3D printed molds can still be modified and adjusted using traditional methods. The results show that 3D printed molds are feasible for thermoforming prosthetic and orthotic devices such as prosthetic sockets while providing new flexibility.

The proposed method for RT of a mold for prosthetic/orthotic manufacturing provides great flexibility in the manufacturing and fitting process while maintaining proven materials in the final device provided to patients. This flexibility increases the value of digital medical records and efforts to develop model‐based approaches to prosthetic/orthotic device design by providing a readily available process for recreating molds. Depending on the needs of the practitioners and patients, 3DP can be incorporated at a variety of points in the manufacturing process.

The purpose of this paper is to determine the most‐practical means of transforming computer‐aided‐design models of custom clubfoot pedorthoses into functional pedorthoses for testing on patients in a clinical trial.

The materials used in conventional orthosis fabrication are not yet available for solid free‐form fabrication; therefore, to fabricate the pedorthoses, several approaches were considered, including direct manufacturing, additive‐based moulding, laser cutting of foam and combinations of several of these approaches.

The chosen approach of additively manufacturing the custom hard shell, and moulding the polyurethane‐foam insert, resulted in accurate, durable and effective pedorthoses that fit well, and could be adjusted as needed. The pedorthoses that were produced are currently being tested on the respective patients for their improvement in mobility and degree of clubfoot correction, and will continue through early 2010.

Additive manufacturing provides an ideal approach for generating the custom, end‐use hard‐ and soft‐layer patterns: each pedorthosis is truly unique; and the soft layer has regions of variable thickness. The advantage of this approach is the reduction in labour and the increase in degrees of design freedom available, compared to conventional methods of fabricating orthotic devices. Replacement inserts can be moulded in a matter of hours using this silicone‐moulding approach.

Several new approaches for fabricating custom orthotic devices were explored, and the related results are discussed. The goal of this paper is to convey the potential of the fabrication procedure used and lessons learned on this project to the rapid prototyping and orthotic communities.

This study aims to investigate the fabrication of solid ankle foot orthoses (SAFOs) using fused deposition modeling (FDM) printing technology. It emphasizes cost-effective 3D scanning with the Kinect sensor and conducts a comparative analysis of SAFO durability with varying thicknesses and materials, including polylactic acid (PLA) and carbon fiber-reinforced (PLA-C), to address research gaps from prior studies.

In this study, the methodology comprises key components: data capture using a cost-effective Microsoft Kinect® Xbox 360 scanner to obtain precise leg dimensions for SAFOs. SAFOs are designed using CAD tools with varying thicknesses (3, 4, and 5 mm) while maintaining consistent geometry, allowing controlled thickness impact investigation. Fabrication uses PLA and PLA-C materials via FDM 3D printing, providing insights into material suitability. Mechanical analysis uses dual finite element analysis to assess force–displacement curves and fracture behavior, which were validated through experimental testing.

The results indicate that the precision of the scanned leg dimensions, compared to actual anthropometric data, exhibits a deviation of less than 5%, confirming the accuracy of the cost-effective scanning approach. Additionally, the research identifies optimal thicknesses for SAFOs, recommending a 4 and 5 mm thickness for PLA-C-based SAFOs and an only 5 mm thickness for PLA-based SAFOs. This optimization enhances the overall performance and effectiveness of these orthotic solutions.

This study’s innovation lies in its holistic approach, combining low-cost 3D scanning, 3D printing and computational simulations to optimize SAFO materials and thickness. These findings advance the creation of cost-effective and efficient orthotic solutions.

The purpose of this paper is to quantitatively assess the three-dimensional (3D) geometry and symmetry of the torso for spinal deformity and the use of orthotic bracewear by using non-invasive 3D body scanning technology.

In pursuing greater accuracy of body anthropometric measurements to improve the fit and design of apparel, 3D body scanning technology and image analysis provide many more advantages over the traditional manual methods that use contact measurements. To measure the changes in the torso geometry and profile symmetry of patients with adolescent idiopathic scoliosis, five individuals are recruited to undergo body scanning both with and without wearing a rigid brace during a period of six months. The cross-sectional areas and profiles of the reconstructed 3D torso models are examined to evaluate the level of body symmetry.

Significant changes in the cross-sectional profile are found amongst four of the patients over the different visits for measurements (p < 0.05), which are consistent with the X-rays results. The 3D body scanning system can reliably evaluate changes in the body geometry of patients with scoliosis. Nevertheless, improvements in the symmetry of the torso are found to be somewhat inconsistent among the patients and across different visits.

This pilot study demonstrates a practical and safe means to measure and analyse the torso geometry and symmetry so as to allow for more frequent evaluations, which would result in effective and optimal treatment of spinal deformation.

This paper demonstrates, using empirical cases from the National Health Services (NHS), how existing practices in demand specification, procurement and supply management fail to address the significant problems caused by the misalignment of demand and supply. When examining internal demand management a number of problems arise including: product overspecification, premature establishment of design and specification, frequent changes in specification, poor demand information, fragmentation of spend, maverick buying, inter-departmental power and politics, and the risk-averse nature and culture of the organisation. It is argued that unless these problems are addressed and eliminated the NHS will not be in a position to select the most appropriate reactive or proactive approach from the range of sourcing options available. An improvement path that NHS Trusts might follow to achieve more efficient and effective procurement and supply management is outlined.

There are over 40 million amputees globally with more than 185,000 Americans losing their limbs every year. For most of the world, prosthetic devices remain too expensive and uncomfortable. This paper aims to outline advancements made by a multidisciplinary research group, interested in advancing the restoration of human motion through accessible lower limb prostheses.

Customization, comfort and functionality are the most important metrics reported by prosthetists and patients. The work of this paper presents the design and manufacturing of a custom made, cost-effective and functional three-dimensional (3D) printed transtibial prosthesis monocoque design. The design of the prosthesis integrates 3D imaging, modelling and optimization techniques coupled with additive manufacturing.

The successful fabrication of a functional monocoque prosthesis through 3D printing indicates the workflow may be a solution to the worldwide accessibility crisis. The digital workflow developed in this work offers great potential for providing prosthetic devices to rural communities, which lack access to skilled prosthetic physicians. The authors found that using the workflow together with 3D printing, this study can create custom monocoque prostheses (Figure 16). These prostheses are comfortable, functional and properly aligned. In comparison with traditional prosthetic devices, the authors slowered the average cost, weight and time of production by 95%, 55% and 95%, respectively.

This novel digital design and manufacturing workflow has the potential to democratize and globally proliferate access to prosthetic devices, which restore the patient’s mobility, quality of life and health. LIMBER’s toolbox can reach places where proper prosthetic and orthotic care is not available. The digital workflow reduces the cost of making custom devices by an order of magnitude, enabling broader reach, faster access and improved comfort. This is particularly important for children who grow quickly and need new devices every few months or years, timely access is both physically and psychologically important.

In this manuscript, the authors show the application of digital design techniques for fabricating prosthetic devices. The proposed workflow implements several advantageous changes and, most importantly, digitally blends the three components of a transtibial prosthesis into a single, 3D printable monocoque device. The development of a novel unibody transtibial device that is properly aligned and adjusted digitally, greatly reduces the number of visits an amputee must make to a clinic to have a certified prosthetist adjust and modify their prosthesis. The authors believe this novel workflow has the potential to ease the worldwide accessibility crisis for prostheses.

Ankle–foot orthoses (AFOs) are assistive devices prescribed for a number of physical and neurological disorders affecting the mobility of the lower limbs. Additive manufacturing has been explored as an alternative process; however, it has proved to be inefficient cost-wise. This work aims to explore the possibilities of generating modular AFO elements, namely, calf, shank and footplate, with the localized composite reinforcement that aids in the optimization of the device in terms of functionality, aesthetics, rigidity and cost.

The conventional lower leg–foot orthosis configuration depends on thermoforming a polymer sheet around a mortar cast with a trademark firmness relying upon the trim-line with the inalienable plan restrictions. In manufacturing of AFO the expert, i.e. orthotist's, guidance is used. Polypropylene and polyethylene material is used in fabrication of AFO to complete all-round reported points of interest over the ordinary outlines, yet their mechanical conduct under administration conditions cannot be effectively anticipated.

AFOs made of polypropylene and polyethylene material are available in the market, which are used by children of age 3-5 years. With the existing AFO design, patients are facing excessive heating and sweating problems during long-term usage. After feedback from patients and orthotists (who prescribed AFO to patients), an attempt has been made to solve the problem with a new and improved AFO design of AFO by using finite element modelling and stress analysis. Also, the results indicate that the new design is similar to the actual product design.

This work introduces the low-cost 3D printing with reinforcement approach as an alternative route for the designing and manufacturing of orthotic devices with complex shapes. It is expected that new applications add-up to increase the body of knowledge about the behaviour of such products which will mix both areas, composite theory and additive manufacturing. This study investigated the fields related to 3D scanning, 3D printing and computer-aided designing for the manufacturing of a customized AFO.

The purpose of this paper is to describe a novel design workflow for the digital fabrication of custom-made orthoses (CMIO). It is intended to provide an easier process for clinical practitioners and orthotic technicians alike. It further functions to reduce the dependency of the operators’ abilities and skills.

The technical assessment covers low-cost three-dimensional (3D) scanning, free computer-aided design (CAD) software, and desktop 3D printing and acetone vapour finishing. To analyse its viability, a cost comparison was carried out between the proposed workflow and the traditional CMIO manufacture method.

The results show that the proposed workflow is a technically feasible and cost-effective solution to improve upon the traditional process of design and manufacture of custom-made static trapeziometacarpal (TMC) orthoses. Further studies are needed for ensuring a clinically feasible approach and for estimating the efficacy of the method for the recovery process in patients.

The feasibility of the process increases the impact of the study, as the great accessibility to this type of 3D printers makes the digital fabrication method easier to be adopted by operators.

Although some research has been conducted on digital fabrication of CMIO, few studies have investigated the use of desktop 3D printing in any systematic way. This study provides a first step in the exploration of a new design workflow using low-cost digital fabrication tools combined with non-manual finishing.