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<p>Ankle–foot orthoses (AFOs) are essential assistive devices for patients experiencing trouble lifting or stabilizing their foot due to various conditions. Traditional AFO fabrication methods are labor-intensive and time-consuming. This study presents a systematic approach to optimize the fabrication of patient-specific ankle–foot orthoses (AFOs) using a gray relational analysis (GRA)-based Taguchi method combined with 3D scanning, finite element analysis (FEA), and additive manufacturing. Tensile specimens were fabricated using fused deposition modeling (FDM) under varying printing conditions, and their tensile strength and surface roughness were analyzed to identify optimal parameters. The optimized combination—triangular infill pattern, nozzle temperature of 225&#xa0;°C, print speed of 15&#xa0;mm/s, and layer thickness of 0.1&#xa0;mm—yielded a tensile strength of ∼ 28&#xa0;MPa and surface roughness reduced to ∼ 2.5&#xa0;µm for polypropylene (PP) specimens. These optimized parameters were then applied to a custom-designed AFO model generated from patient-specific 3D scans. Mechanical performance of the optimized AFO was validated through FEA in ANSYS and confirmed by a patient trial, which demonstrated adequate rigidity and comfort. The proposed framework reduces experimental effort while achieving enhanced mechanical performance, providing a novel and efficient pathway for patient-specific AFO fabrication.</p>

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Customized Ankle–Foot Orthoses Fabrication via the Combined Approach of Design of Experiment, Additive Manufacturing, and Finite Element Analysis

  • 期刊论文

  • 发表日期：

    2025年11月10日

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  • Hong Hieu Le,
  • Thanh Hien Nguyen,
  • Bui Quoc Huy Nguyen

摘要

Ankle–foot orthoses (AFOs) are essential assistive devices for patients experiencing trouble lifting or stabilizing their foot due to various conditions. Traditional AFO fabrication methods are labor-intensive and time-consuming. This study presents a systematic approach to optimize the fabrication of patient-specific ankle–foot orthoses (AFOs) using a gray relational analysis (GRA)-based Taguchi method combined with 3D scanning, finite element analysis (FEA), and additive manufacturing. Tensile specimens were fabricated using fused deposition modeling (FDM) under varying printing conditions, and their tensile strength and surface roughness were analyzed to identify optimal parameters. The optimized combination—triangular infill pattern, nozzle temperature of 225 °C, print speed of 15 mm/s, and layer thickness of 0.1 mm—yielded a tensile strength of ∼ 28 MPa and surface roughness reduced to ∼ 2.5 µm for polypropylene (PP) specimens. These optimized parameters were then applied to a custom-designed AFO model generated from patient-specific 3D scans. Mechanical performance of the optimized AFO was validated through FEA in ANSYS and confirmed by a patient trial, which demonstrated adequate rigidity and comfort. The proposed framework reduces experimental effort while achieving enhanced mechanical performance, providing a novel and efficient pathway for patient-specific AFO fabrication.