Materials and Manufacturing for Ankle–Foot Orthoses: A Review

Abstract

Ankle‐foot orthoses (AFOs) assist patients with gait impairment by correcting ankle and foot deformities, restoring mobility, reducing pain, and providing protection and immobilization. AFOs can beneficially manage various types of gait pathologies, including foot drop, crouch gait, equinus gait, and stiff knee gait. AFOs are produced in prefabricated or custom‐made forms in various designs. The selection criteria for the fabrication of an AFO are the duration of usage, the amount of applied force, the degree of axial loading, the patient’s skin condition, and the cost. The accessibility of diverse materials in the past century has greatly advanced orthoses. The ideal orthotic materials must be light, stiff, and strong, and are made of plastics, metals, polymer‐based composites, leather, or a hybrid of different materials. Deeper understanding of the materials employed in the fabrication of AFOs will lead to more advanced and efficient orthoses, which can improve patients’ ability to ambulate in the real world. The present review provides insight into the various materials utilized for the fabrication of AFOs and describes the benefits and challenges associated with these materials. An attempt has also been made to highlight typical gait pathologies and design concepts in response to these.This article is protected by copyright. All rights reserved.

Design and analysis of solid ankle foot orthosis by employing mechanical characterization and a low-cost scanning approach for additive manufacturing

“…This level of customization ensures a more comfortable fit and better therapeutic outcomes. Traditional manufacturing methods often involve labor-intensive processes and may result in a less precise fit, which can impact the effectiveness of the orthotic intervention (Nouri et al, 2023). The AM of AFOs using FDM is still in its infancy.…”

“…In contrast to conventional manufacturing techniques, AM offers a streamlined and more efficient production process. Traditional methods use a series of steps, including molding and shaping, which can be time-consuming, while the AM significantly reduces lead times, allowing patients to receive their customized AFOs more quickly (Nouri et al. , 2023).…”

Assessment of consolidative multi-criteria decision making (C-MCDM) algorithms for optimal mapping of polymer materials in additive manufacturing: A case study of orthotic application

“…Orthoses may be classified into two categories: custom-made or prefabricated [ 16 ]. Prefabricated orthoses are readily available in standardized sizes, and frequently need adjustments to adequately conform to the user's anatomical structure and specific requirements.…”

“…The duration of this procedure might vary from a minimum of two days to several weeks, depending upon the extent of postprocessing that is necessary. In contrast, personalized (or custom-made) orthoses exhibit superior conformity to the patient's anatomical structure and demonstrate enhanced performance compared to prefabricated orthotic devices [ 16 ]. According to research conducted at the prosthetic care facility, it was found that the primary determinant of satisfaction among orthosis users is their level of fitness [ 19 ].…”

“…The manufacturing process, design elements, and the materials used have a substantial impact on the efficacy and performance of an orthosis [ 16 ]. Improved production processes and the utilization of higher-quality materials can limit amputee risks and lower maintenance costs while simultaneously enhancing the fitting and usefulness.…”