Professional Documents
Culture Documents
David Palousek
Faculty of Mechanical Engineering, Brno University of Technology, Brno, Czech Republic
Jiri Rosicky
Faculty of Health Studies, University of Ostrava, Ostrava, Czech Republic, and
1. Introduction
1.1 Motivation
The current state of knowledge allows a solution of the
production of upper limb orthoses using advanced technologies
such as rapid prototyping (RP) and reverse engineering (RE).
These approaches, nowadays in common practice, allow the
realization of products on a higher level, especially in terms of
design and comfort of use. The question is: are these technologies
able to be effectively implemented to make an orthosis for the
upper limb and thus improve its functional characteristics? Are
the technologies effective and affordable and are the procedures
reliable in results? Can the manufacturing process be significantly
simplified? This case study tries to provide the answers to the
aforementioned questions. The case study was developed in
cooperation with a manufacturer of prosthetic and orthotic
devices in the Czech Republic and focuses on the manufacturing
process, and intends to explore the feasibility of the approach.
1.2 Manufacturing
Orthoses are used for the immobilisation of the forearm, wrist
and hand to relieve long-term conditions or support
injured limbs. It also serves as a substitute for plaster splints
after surgery. The production of the orthosis is accomplished by
The work described in this paper was completed in cooperation with the
orthotic-prosthetic facility ING Corporation, s.r.o. in Frydek-Mistek and
the Department of Rehabilitation, Faculty of Health Studies, University of
Ostrava and the Institute of Machine and Industrial Design Faculty of
Mechanical Engineering, Brno University of Technology. The present
work has been supported by European Regional Development Fund in the
framework of the research project NETME Centre under the Operational
Programme Research and Development for Innovation NETME
Centre, ED0002/01/01, CZ. 1.05/2.1.00/01.0002. All the authors declare
that they have no conflicts of interest.
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2. Methods
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3. Discussion
An innovative methodology of design and manufacture of the
wrist orthosis using digital technologies throughout the whole
design cycle, including production, has been presented. It mainly
concerns itself with optical digitizing, RE, CAD modeling and RP.
The work process of the modeling and creation of a 3D
geometry of the orthosis from data obtained by scanning the
upper limb was practically verified. The application of the RE
software and SolidWorks 3D parametric modeler allows faster
design work and the creation of a high-quality geometric model.
Based on similar CAD applications, a more efficient use of time
is likely to be found. The demands on design and software skills
of the designer entail basic knowledge of RE and an
intermediate level of CAD.
A faultless geometry model is necessary for smooth
transition to the next phase of the design process, which is
the production of a fully functional prototype.
First, an RP technology ZPrinter 3D printing was used for
verification of the design. It was possible to test the function
of the connecting elements and verify the orthosis
ergonomics. In terms of ergonomics, the ZPrinter orthosis
met the expectations.
Therefore, for the second prototype, FDM technology that
works with ABS plastic (a factory designation of ABS ) was
selected. Thanks to ABS, the orthosis was more flexible and
more resistant to bending stress, and also the connection hooks
for the metal clips are not prone to cracking or breaking
(Figure 6).
Mechanical properties of layered ABS plastic were measured
using the tensile and bending tests (Figure 7). For each
measurement, six samples were used. Three measurements of
tensile test and three measurements of bending test were carried
out with respect to the different orientations of the sample
during building process (Figure 6). Measurements were taken
according to ASTM D 638-03 and ASTM D 790-03.
For comparison, the results of tensile and bending tests for
high-temperature copolymer polypropylene (CPP, Premium
Grade copolymer polypropylene, North Sea Plastics Ltd,
Glasgow, UK) and tensile tests of Aquaplast (Orfit Classic Soft,
Orfit Industries n.v., Wijnegem, Belgium) have been provided.
The measured values of ultimate tensile strength are shown
in Table I. The values varied in the order of units, therefore
the presented values have been arithmetically averaged.
Tension
Flat position
On the side
Upright
Bending
Flat position
On the side
Upright
30
25
30
12
26.5
17
52
60
23
44.5
3.3 Patient
The implementation of CAD and Additive Manufacture in
the production of orthoses could contribute to increased
speed of production and patient comfort.
This study does not aim to carry out clinical tests. In practice
(Czech Republic) clinical requirements for the orthosis (effect
of the orthosis, the position of the limb) are prescribed by
specialists (orthopedist, a surgeon, rehabilitation doctor) who
are responsible for its clinical efficacy, as indicated in the
introduction. The orthotics are responsible for the technical
performance of the orthosis. However, if the presented
methodology would be used in practice as an alternative
method of production, a clinical validation will be necessary.
4. Conclusions
The RP of orthosis or prosthesis itself significantly accelerates
the process of the patients integration back into their
social environment. An aim of all medical centres and
organizations is to increase the patients comfort and improve
the environment in which the orthotic or prosthetic devices are
developed and tested. The possibility of a combination of the
rapid manufacture of orthoses and patient comfort without
reducing the quality of the final products could bring the interest
of medical facilities to the ideas of the implementation of new
technologies such as 3D scanning of the human body, the
manufacturing of functional prototypes by RP methods or, in
the near future, Direct Digital Manufacturing.
In conclusion, it is necessary to answer the questions set in
the motivation. The costs of using digitization technologies
and additive manufacturing are, of course, relatively high.
3.2 Implementation
The implementation of this workflow in practice depends
primarily on the development of 3D printers, used building
materials and their properties, and overall costs. At present, this
procedure is not economically feasible in comparison
with standard manufacturing methods of similar orthosis
types (Table II). Time cost of the standard procedure depends
on whether it uses low-temperature plastic moldable on the
hand (1-3 hours), or high-temperature thermoplastic or
laminate (5-10 hours).
In the case of the production of custom-made WHO types
of orthoses (or similar types) in larger quantities, it would be
advantageous to automate some of the design phases using
macros by a modeler which allows their creation (e.g. the
software programs Rhinoceros, Rapidform, etc.).
Figure 8 Deviation between orthosis and hand scan
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Time (h)
3D digitizing, post-processing
Polygonal data processing
Surface generating
CAD model creation (primary)
RP FDM part building
Surface finishing
Total
0.2
1
2
6
9.5
5
23.7
References
Ahn, S.H., Montero, M., Odell, D., Roundy, S. and
Wright, P.K. (2002), Anisotropic material properties of
fused deposition modeling ABS, Rapid Prototyping Journal,
Vol. 8 No. 4, pp. 248-257.
Chimento, J., Highsmith, M.J. and Crane, N. (2011), 3D
printed tooling for thermoforming of medical devices,
Rapid Prototyping Journal, Vol. 17 No. 5, pp. 387-392.
Cook, D., Gervasi, V., Rizza, R., Kamara, S. and Liu, X.C.
(2010), Additive fabrication of custom pedorthoses for
clubfoot correction, Rapid Prototyping Journal, Vol. 16
No. 3, pp. 189-193.
Further Reading
Jain, M.L., Govind Dhande, S. and Vyas, N.S. (2011),
Virtual modeling of an ankle foot orthosis for correction of
foot abnormality, Robotics and Computer-Integrated
Manufacturing, Vol. 27 No. 2, pp. 257-260.
Corresponding author
David Palousek can be contacted at: palousek@fme.vutbr.cz
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