Design and manufacture of a custom ankle–foot orthoses using traditional manufacturing and fused deposition modeling

Additive manufacturing (AM) has the ability to design ankle–foot orthosis (AFO) using different materials, shapes, and sizes with characteristics for functional and reliable clinical applications. Nowadays, for custom-AFOs for the patients, the designers are looking for optimization of weight, shape, structures, thickness and functional characteristics using AM. The objective of this study is to manufacture a customized AFO using AM with fused deposition modeling (FDM) and also compare it with traditional manufacturing route. Dimensions were measured using a 3D scanner, followed by CAD modeling and manufacture with AM using FDM. The model fit was then tested for mechanical properties, vibration analysis and flexibility of the AFO. A clinical case study methodology was applied to a 22-year-old patient suffering from drop-foot and the patient showed improved gait performance. The study showed that FDM based framework is best suited for the application of designer/customized AFO being more flexible, light in weight and took lesser manufacturing time compared to traditional manufacturing.