Design and FDM Additive Manufacturing of a Bespoke Modular Orthopaedic Corset for Patients with Spinal Problems

Patients with spinal problems have difficulty when performing activities of daily living due to weakness or paralysis in the joints and muscular system, and this is a serious problem for people of all ages because it negatively affects their socio, physio, and economic lives. Traditional orthopedic corsets are a valuable support for these patients because these devices enable them to perform specific activities that require motor control, such as sitting, walking and other physical activities. However, they are often bulky, poorly ventilated and manufactured with non-biocompatible materials. This research focuses on the design and manufacturing of bespoke orthopedic corsets through a new organic bioplastic compound, optimizing the aspects of functionality, light weight, and small footprint. The developed orthosis offers design flexibility and improved porosity control, performing the functions of an exoskeleton, assisting patients with spinal problems who cannot be operated on because they have high risks during surgery, e.g., herniated disc, osteoporosis, injury, osteoarthritis, etc. It allows pain relief and the continuation of even the simplest activities of daily living making patients more independent. The most suitable materials, such as polymers and their composites, were evaluated to manufacture a customized and biodegradable orthosis. Future goals include automating the process of designing and printing the customized orthosis from a real-time scan of the patient's torso.