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<p>This study presents an innovative framework for the design and evaluation of anatomically appropriate Solid Ankle-Foot Orthoses through finite element analysis guided by ISO 10328 standards. A total of six materials representing three manufacturing strategies were investigated: conventional thermoplastics (polypropylene, high-density polyethylene), clinically established composites (epoxy carbon woven, orthocrylic resin/perlon woven), and novel additive manufacturing polymers (polylactic acid, acrylonitrile butadiene styrene). Material and thickness-dependent responses were assessed under position-specific loading conditions, reflecting regulatory requirements for weight categories. The simulations revealed distinct deformation and stress distribution patterns, with forefoot concentration in Position I and stress shifts near the ankle in Position II. Safety factors improved with increased thickness, but material class critically influenced structural integrity. The analyses revealed that maximum deformation ranged between 0.13 and 86.38&#xa0;mm depending on material type and thickness, with epoxy carbon woven and polylactic acid showing the lowest deformation at 3&#xa0;mm thickness for Position I and II in P3 patient category. Maximum Von Mises stresses varied between 5.52 and 122.59&#xa0;MPa, while advanced composite material orthocrylic resin/perlon woven exhibited the lowest stress levels under ISO-defined loading conditions. Safety factors ranged from 0.25 to 15.00 across all configurations, demonstrating that optimal performance was achieved at all thickness for epoxy carbon woven, at ≥ 4&#xa0;mm for polylactic acid and orthocrylic resin/perlon woven, and at ≥ 5&#xa0;mm for the rest of the materials. These findings quantify the biomechanical superiority of composite laminates, emphasize the nonlinear interaction between material class and thickness, and demonstrate that ISO-based loading provides a robust and clinically relevant framework for orthotic structural assessment. Also, reveal promising performance expectations from additive manufacturing polymers compared to conventional thermoplastics. By integrating FEA with regulatory loading standards, this study offers a reliable pathway toward high-performance, cost-effective AFO design while reducing dependence on physical prototyping.</p>

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Finite Element Analysis of Rigid Ankle-Foot Orthoses: Validation and Material Performance of Traditional, Composite, and 3D-Printable Materials

  • 期刊论文

  • 发表日期：

    2026年3月16日

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  • Yunis Akkaş,
  • Ahmet Gökhan Acar,
  • Serap Alsancak

摘要

This study presents an innovative framework for the design and evaluation of anatomically appropriate Solid Ankle-Foot Orthoses through finite element analysis guided by ISO 10328 standards. A total of six materials representing three manufacturing strategies were investigated: conventional thermoplastics (polypropylene, high-density polyethylene), clinically established composites (epoxy carbon woven, orthocrylic resin/perlon woven), and novel additive manufacturing polymers (polylactic acid, acrylonitrile butadiene styrene). Material and thickness-dependent responses were assessed under position-specific loading conditions, reflecting regulatory requirements for weight categories. The simulations revealed distinct deformation and stress distribution patterns, with forefoot concentration in Position I and stress shifts near the ankle in Position II. Safety factors improved with increased thickness, but material class critically influenced structural integrity. The analyses revealed that maximum deformation ranged between 0.13 and 86.38 mm depending on material type and thickness, with epoxy carbon woven and polylactic acid showing the lowest deformation at 3 mm thickness for Position I and II in P3 patient category. Maximum Von Mises stresses varied between 5.52 and 122.59 MPa, while advanced composite material orthocrylic resin/perlon woven exhibited the lowest stress levels under ISO-defined loading conditions. Safety factors ranged from 0.25 to 15.00 across all configurations, demonstrating that optimal performance was achieved at all thickness for epoxy carbon woven, at ≥ 4 mm for polylactic acid and orthocrylic resin/perlon woven, and at ≥ 5 mm for the rest of the materials. These findings quantify the biomechanical superiority of composite laminates, emphasize the nonlinear interaction between material class and thickness, and demonstrate that ISO-based loading provides a robust and clinically relevant framework for orthotic structural assessment. Also, reveal promising performance expectations from additive manufacturing polymers compared to conventional thermoplastics. By integrating FEA with regulatory loading standards, this study offers a reliable pathway toward high-performance, cost-effective AFO design while reducing dependence on physical prototyping.