Effectiveness of 3D printed carbon fiber composite strut in customized ankle foot orthosis

Abstract

This study aims to fabricate customized Ankle Foot Orthosis (cAFO) using Additive Manufacturing (AM), for investigating the effectiveness of straight Carbon Fibre Strut (CFS) that enhances push-off limits of drop foot (DF) gait. Three patients with unilateral DF were studied and two different host materials were used to fabricate cAFO from two different AM machines. A comparative quantitative study between the gait pattern of normal foot and DF (on affected side for same patient) for CFS efficacy was done by conducting two gait trials: with and without cAFO. The study shows CFS with cAFO is an effective additive manufactured mechanical component for DF patients to improve lower extremity functionality. CFS stores and releases energy during various phases of the gait cycle required for normal gait functionality for instance an improvement can be seen in deviation in ankle power to +36.84 % and +60.57 % for patients under consideration. In design domain, previous studies confined to L shaped strut, also clinical validation of straight strut is very limited. In this article clinical validation of straight strut with rectangular cross-section on DF patient is presented by using state-of-the-art tools, gait lab and design software's, resulting in better customization and ankle–foot mobility with reduced plantarflexion.