Manufacture of a Custom-Made AFO Orthosis Based on Abaca Nonwoven Composite (Musa Textilis) and Resin

Orthoses support, stabilize, and correct the ankle and foot. This research focuses on manufacturing a mold for a prototype orthosis aimed at developing a low-cost manufacturing methodology. Many materials can be used in an orthopedic device. This study considers a composite material of 80 g/cm2 abaca nonwoven fiber, epoxy resin, and polyester. The experimental planning is executed with a 22-factorial design with 12 experimental runs, and parameters such as the effect of resin type and nonwoven fabric are evaluated. The response variables are tensile strength (TS) and flexural strength (FS), and the samples are prepared according to the procedure described in ISO 1421:1998 (tensile strength). The TS is evaluated using the Titan 5 James Heal Dynamometer. At the same time, the FS is assessed according to the procedure in ASTM D7264 using the three-point bending test technique on the AUTOGRAPH machine. The statistical analysis is performed using Statgraphics Centurion software. It is demonstrated that there is a significant difference in tensile and flexural strength when changing the resin type and nonwoven fabric levels. This research concludes that it is feasible to manufacture orthoses with natural abaca fibers and thermosetting plastic resins such as polyester and epoxy.