Design and development of orthosis for clubfoot correction in infants an additive manufacturing approach

Abstract

Clubfoot is a rare complex congenital deformity found in new born babies, with foot twisted inwards and downward. This condition, if not treated at infancy, may lead to permanent deformity. The victims suffer pain and difficulty in walking which result in failure to access education and employment leading to exclusion from society. Patients suffering from this deformity can be seen throughout the world and are generally mistaken to be affected by polio. The only non-invasive treatment is use of casting method (Ponseti) which has wide range of disadvantages. This method has not been properly substituted due to the lack of a better alternative. Current study suggests the development of a custom – made orthosis. 3D printing technique can be used to fabricate this deformity correction orthosis. The 3D printed orthosis has an upper hand over the conventional casting process. Various parameters related to the treatment were considered in designing the orthosis. Prominent parameters being three dimensional movements, ease of use, comfort, immobilization and cost. The orthosis can be used throughout the treatment process without frequent replacement; this is a distinct advantage over the Ponseti method. The orthosis will replace the casting process and will prove to provide better treatment. Even though printing the orthosis on spot takes longer time than the conventional cast, its countless benefits make up for the waiting time. In the current work design and development of orthosis is achieved with CAD software and fabrication is made with FDM 3D printer using PLA filament.