A novel workflow to fabricate a patient-specific 3D printed accommodative foot orthosis with personalized latticed metamaterial

Hudak, Yuri F.; Li, Jingsheng; Cullum, Scott; Strzelecki, Brian; Richburg, Chris A.; Kaufman, G. Eli; Abrahamson, Daniel C.; Heckman, Jeffrey; Ripley, Beth; Telfer, Scott; Ledoux, William R.; Muir, Brittney C.; Aubin, Patrick M.

doi:10.1016/j.medengphy.2022.103802

Cited by 18 publications

(27 citation statements)

References 35 publications

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“…Most orthoses are parts with complex shapes, and for this reason, it is almost impossible and very expensive to personalize them for each patient in a conventional production way [ 189 ]. In Figure 32 , different complex 3D printed orthoses devices, for the lower and upper extremities, are presented [ 189 , 190 , 191 , 192 , 193 , 194 ].…”

Section: Complexity Of Additive Manufactured Partsmentioning

confidence: 99%

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Influence of Process Parameters on the Characteristics of Additively Manufactured Parts Made from Advanced Biopolymers

et al. 2023

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Over the past few decades, additive manufacturing (AM) has become a reliable tool for prototyping and low-volume production. In recent years, the market share of such products has increased rapidly as these manufacturing concepts allow for greater part complexity compared to conventional manufacturing technologies. Furthermore, as recyclability and biocompatibility have become more important in material selection, biopolymers have also become widely used in AM. This article provides an overview of AM with advanced biopolymers in fields from medicine to food packaging. Various AM technologies are presented, focusing on the biopolymers used, selected part fabrication strategies, and influential parameters of the technologies presented. It should be emphasized that inkjet bioprinting, stereolithography, selective laser sintering, fused deposition modeling, extrusion-based bioprinting, and scaffold-free printing are the most commonly used AM technologies for the production of parts from advanced biopolymers. Achievable part complexity will be discussed with emphasis on manufacturable features, layer thickness, production accuracy, materials applied, and part strength in correlation with key AM technologies and their parameters crucial for producing representative examples, anatomical models, specialized medical instruments, medical implants, time-dependent prosthetic features, etc. Future trends of advanced biopolymers focused on establishing target-time-dependent part properties through 4D additive manufacturing are also discussed.

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Section: Complexity Of Additive Manufactured Partsmentioning

confidence: 99%

“… Orthosis devices for ( a ) neck [ 193 ], ( b ) finger [ 189 ], ( c ) hand [ 190 ], ( d ) knee [ 191 ], ( e ) ankle [ 194 ], and ( f ) foot [ 192 ]. …”

Section: Figurementioning

confidence: 99%

Influence of Process Parameters on the Characteristics of Additively Manufactured Parts Made from Advanced Biopolymers

et al. 2023

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“…1,12,[15][16][17][18] Therefore, comfort evaluation is essential 8 because the perception of poor comfort 6 may lead to poor user compliance. 30,31 Other crucial things are the correct shoe size, adequate space 19 for the exact insole inside, which is in contact 5,8,18 with the foot during all dynamic and postural movements, 9 such as standing, walking, and running. 5, It is precisely for this purpose that digitizing dimensions is of great importance.…”

Section: Introductionmentioning

confidence: 99%

3D Printing of Individual Running Insoles – A Case Study

Danko,

Sekac,

Dzivakova

et al. 2023

ORR

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The study's starting point is to find a low-cost and best-fit solution for comfortable movement for a recreational runner with knee pain using an orthopedic device. It is a case study. The research aims to apply digitization, CAD/CAM tools, and 3D printing to create an individual 3D running insole. The objective is to incorporate flexible shape optimization would provide comfort reductions in foot plantar pressures in one subject with knee pain while running. The test hypothesis was if it is possible to make it from one material. For this purpose, we created a new digital workflow based on the Decision Tree method and analyzed pain and comfort scores during user testing of prototypes. Patient and Methods: The input data were obtained during a professional examination by a specialist doctor in the orthopedic outpatient clinic in the motion laboratory (DIERS 4D Motion Lab, Germany) with the output of data on the proband's complex movement stereotype. Surface and volumetric data were obtained in the biomedical laboratory with the 3D scanner. We modified the digital 3D foot models in 3D mesh software, developed the design in SW Gensole (Gyrobot, UK), and finally incorporated the internal structure and the surface layer of the insole data of the knowledge from the medical examination, comfort analyses, and scientific studies findings. Results: Four complete 3D-printed prototypes (n=4) with differences in density and correction elements were designed. All of them were fabricated on a 3D printer (Prusa i3 MK3S, Czech Republic) with flexible TPU material suitable for skin contact. The Participant tested each of them five times in the field during a workout and final insoles three months on the routine training. Conclusion: A novel workflow was created for designing, producing, and testing full 3D-printed insoles. The product is fit for immediate use.

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“…DLS can manufacture metamaterials with fine‐tuned mechanical properties, such as personalized latticed foot insoles for diabetes patients. [ 40 ]…”

Section: Introductionmentioning

confidence: 99%

“…DLS can manufacture metamaterials with fine-tuned mechanical properties, such as personalized latticed foot insoles for diabetes patients. [40] This work combines AM and machine learning (ML) to demonstrate the effective data-driven design of nonlinear elastomeric springs with prescribed responses. Our design is based on χ-spring, [41] where χ is the Greek letter "chi," which has two DOI: 10.1002/aisy.202200225 Architected metamaterials exhibit complex stress-strain responses, such as quasi-zero stiffness (QZS) plateau response useful in vibration and energy absorption, by exploiting elastic instabilities such as buckling.…”

Section: Introductionmentioning

confidence: 99%

Modeling and Design of Zero‐Stiffness Elastomer Springs Using Machine Learning

Kim

Tawfick

King

2022

Advanced Intelligent Systems

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Architected metamaterials exhibit complex stress–strain responses, such as quasi‐zero stiffness (QZS) plateau response useful in vibration and energy absorption, by exploiting elastic instabilities such as buckling. However, the design of metamaterials with prescribed nonlinear mechanical properties is challenging due to the difficulty in accurately predicting nonlinear mechanical responses such as buckling and self‐contact, as well as geometric and material uncertainties. Herein, additive manufacturing (AM) with machine learning (ML) to demonstrate data‐driven modeling and the design of nonlinear elastomeric springs with a broad stress plateau is combined. 243 elastomer chi (χ) spring parts with different design parameters fabricated by AM are tested. A Gaussian process (GP) model is trained on key features of the measured mechanical response and predicts the mechanical response within a 3% error with as few as 97 parts. To account for the geometric and material uncertainties, the GP model to develop an uncertainty‐aware design optimization approach to tailor the mechanical response based on the covariance matrix adaptation evolution strategy (CMA‐ES) is utilized. Excellent agreement is demonstrated between the designed response and measured response over the range of plateau stress considered. The research illustrates the promise of experimental data‐driven approaches and AM in enabling complex material design.

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A novel workflow to fabricate a patient-specific 3D printed accommodative foot orthosis with personalized latticed metamaterial

Cited by 18 publications

References 35 publications

Influence of Process Parameters on the Characteristics of Additively Manufactured Parts Made from Advanced Biopolymers

Influence of Process Parameters on the Characteristics of Additively Manufactured Parts Made from Advanced Biopolymers

3D Printing of Individual Running Insoles – A Case Study

Modeling and Design of Zero‐Stiffness Elastomer Springs Using Machine Learning

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