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<p>Orthotic devices are designed to aid walking and correct musculoskeletal or neuromuscular conditions. Traditionally, materials like thermoplastics and wood have been used, composites have gained traction in this field due to their unique properties. This study considers AFOs fabricated from two composite material combinations: PLA + CF and PETG + CF. It involves a numerical analysis and experimental investigation of the bending and vibrational behaviour of ankle-foot orthoses (AFOs). A 3D scan is used to create a model of the patient’s lower leg and foot. The AFOs’ bending and vibrational behaviours are analysed using Ansys Workbench. The orthoses are fabricated using FDM with the mentioned materials. Flexural analysis is then performed to determine the bending nature of the AFO, which serves as a basis for topology optimization. Additionally, impact hammer testing is done to obtain the vibrational behaviour under impulse excitation observed during heel strike. The results obtained from numerical analysis and experimental analysis are compared, and the effectiveness of using PETG + CF over conventional PLA ʿ CF is corroborated. On this account, numerical simulations and experimental tests confirm that PETG + CF stands above PLA + CF by reducing impact vibrations by 10%. Composites like PETG + CF offer superior mechanical properties and enhanced comfort, making them ideal for individuals with mobility limitations. Furthermore, further investigations in this field could revolutionize orthotics design thus enhancing its supportiveness for the end user.</p>

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Design, Analysis and Testing of Ankle Foot Orthoses (AFOs) Made of Synthetic Fibre Reinforced 3D Printed Polymer Composites

  • 期刊论文

  • 发表日期：

    2025年9月10日

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  • Ved Sudhir Shetty,
  • Vasisht S. Iyer,
  • M. S. Sai Darshan,
  • Pramuk Dinesh,
  • K. S. Srinivasa Prasad

摘要

Orthotic devices are designed to aid walking and correct musculoskeletal or neuromuscular conditions. Traditionally, materials like thermoplastics and wood have been used, composites have gained traction in this field due to their unique properties. This study considers AFOs fabricated from two composite material combinations: PLA + CF and PETG + CF. It involves a numerical analysis and experimental investigation of the bending and vibrational behaviour of ankle-foot orthoses (AFOs). A 3D scan is used to create a model of the patient’s lower leg and foot. The AFOs’ bending and vibrational behaviours are analysed using Ansys Workbench. The orthoses are fabricated using FDM with the mentioned materials. Flexural analysis is then performed to determine the bending nature of the AFO, which serves as a basis for topology optimization. Additionally, impact hammer testing is done to obtain the vibrational behaviour under impulse excitation observed during heel strike. The results obtained from numerical analysis and experimental analysis are compared, and the effectiveness of using PETG + CF over conventional PLA ʿ CF is corroborated. On this account, numerical simulations and experimental tests confirm that PETG + CF stands above PLA + CF by reducing impact vibrations by 10%. Composites like PETG + CF offer superior mechanical properties and enhanced comfort, making them ideal for individuals with mobility limitations. Furthermore, further investigations in this field could revolutionize orthotics design thus enhancing its supportiveness for the end user.