Abstract
Leg orthosis is one of medical device for fracture bone treatment. Several complications have been reported when patients are wearing the conventional Plaster of Paris or fibreglass leg orthosis. Its including numbness due to tight application, swelling, venous congestion and skin irritation. Therefore, the aim of this study is to develop and biomechanical analyse a customized leg cast that could tackle those complications. First, the leg was scanned using a 3D scanner. The leg cast was constructed from a 3D scanned leg model and designed using 3-Matic software which later simulated in finite element analysis using Marc software. The study focuses on three gait cycles; midstance, heel strike and toe off where stress and deformation were predicted. From the results, the cast only supported the ankle in midstance phase with only 7.297MPa stress and not capable to support the ankle in heel strike and toe off phases with maximum stress of 106.99 MPa and 213.12 MPa, respectively, which are beyond its yield strength of ABS, 23MPa. The average of overall displacement occurred for both skin and cast were less than 1.5mm. In short, the cast could only support the ankle in midstance phase and cannot be used for heel strike.
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