Reducing Orthotic Out-Patient Visits from 3 to 1

PROBLEM

Current methods for the design and fabrication of custom orthoses lack accuracy and require multiple visits and long wait times, inconveniencing both patients and providers. Replacing current fabrication techniques with additive manufacturing(AM) provides the potential for mass customization, improved function, and adoption.

This project seeks to address challenges in design methodology for AM throughput, durability, material strength, and system integration.

OBJECTIVE

The objective of this effort is to create a cyber-physical fused deposition modeling (FDM) production system enabling the mass production of individualized orthoses.

The ultimate

goal is to offer “one day visits,” so that patients receive their custom orthosis on the same day that they are evaluated. To achieve the throughput and performance requirements, advancements in design for AM, specialized material offerings, system improvements, and a method to print multiple materials are needed to provide a high quality orthosis.