Using reverse engineering and rapid prototyping for patient specific orthoses

Abstract

Orthotic devices are currently designed to fit a range of patients and therefore they do not provide individualized comfort and function. Using RP methods it is possible to make individual orthosis devices tailored to the individual patient and the disease also characterized by the modern design. A computerized technique for fabricating patient-specific orthotic devices has the potential to provide excellent comfort and allow for changes in the standard design to meet the specific needs of each patient. Reverse engineering methods are combined with rapid prototyping to create patient-specific orthoses. A novel process was engineered to utilize patient-specific surface data of the patient anatomy as a digital input, manipulate the surface data to an optimal form using CAD software, processing also for modern looking and check strength and then processing in rapid prototyping machine for fabrication. The article describes the utilization of rapid prototyping (RP), 3D scanning and software tools for the orthosis design process. This study shows the key points of the design and manufacturing methodology. The approach uses specific technologies, such as 3D digitizing, reverse engineering and polygonal-surface software, SLS RP and 3D printing.