Customized 3D printed ankle-foot orthosis with adaptable carbon fibre composite spring joint

Abstract Neuromuscular disorders and injuries such as cerebral palsy and stroke often result in foot-drop which can result in a person having great difficulty walking. Ankle foot orthoses (AFOs) or splints have been prescribed for many years now to limit the range of motion of the ankle, provide the patients with support and assist with rehabilitation. However the majority of AFOs require a long, labour-intensive manufacturing process which results in unacceptable waiting times for children that are rapidly growing and patients with varying conditions. This research proposes a new approach to AFO manufacturing that utilizes digital and additive manufacturing technologies to customise the fit and form to an individual. By implementing an interchangeable carbon fibre spring at the ankle joint the design will result in a stronger, more comfortable, more flexible AFO that can adaptively constrain ankle movement for various different activities. Three iterations of AFO design have been developed and tested to validate their efficacy. A custom machine has been designed and constructed in order to empirically test stiffness values for the AFO and allow for optimal AFO geometry based on input parameters. This machine has proven the structural integrity of the final AFO design. Progress has been made in automating parts of the design process which will significantly reduce labour requirements and hence manufacturing delay times.