Rapid Prototyping of Personalized Articular Orthoses by Lamination of Composite Fibers upon 3D-Printed Molds

Abstract

Advances in additive manufacturing technologies and composite materials are starting to be combined into synergic procedures that may impact the biomedical field by helping to achieve personalized and high-performance solutions for low-resource settings. In this article, we illustrate the benefits of 3D-printed rapid molds, upon which composite fibers can be laminated in a direct and resource-efficient way, for the personalized development of articular splints. The rapid mold concept presented in this work allows for a flexible lamination and curing process, even compatible with autoclaves. We demonstrate the procedure by completely developing an autoclave-cured carbon fiber–epoxy composite ankle immobilizing, supporting, or protecting splint. These medical devices may support patients in their recovery of articular injuries and for promoting a more personalized medical care employing high-performance materials, whose mechanical response is analyzed and compared to that of commercial devices. In fact, this personalization is fundamental for enhanced ergonomics, comfort during rehabilitation, and overall aesthetics. The proposed design and manufacturing strategies may support the low-cost and user-centered development of a wide set of biomedical devices and help to delocalize the supply chain for involving local populations in the development of medical technology.

Benefits of Non-Planar Printing Strategies Towards Eco-Efficient 3D Printing

“…In addition, a very interesting result is the viability of sequential non-planar 3D printing (method A) repeatedly using a single supporting geometry or mold. This use of FDM as "rapid tooling" technology, for the production of reusable molds and supporting geometries, evolves from previous research by our team [19], but is here validated for nonplanar printing for the first time. After having printed more than 10 insoles upon the test mold, the outer surfaces of the supporting production tool were in perfect condition and no geometrical mismatches or flaws could be appreciated after repeated use.…”

Research Progress of Rehabilitation Orthoses Based on 3D Printing Technology

“…Commonly used materials are divided into rigid materials and fexible materials. Some experts and scholars found that the structural integrity, stifness, low thickness, and patient comfort of orthoses made of additives and composite materials were improved [24].…”

Evaluation of polycarbonate additive manufacturing molds for autoclave molding.

“…Other studies have investigated the validation of the use of FDM layered products as molds for FRP molding by the hand layup method[8, 9] and autoclave molding [10]. Each study showed the potential of FDM layered products as a mold.…”