Cloud-based Design and Additive Manufacturing of Custom Orthoses

This paper presents a cyber design and additive manufacturing (CDAM) system at the University of Michigan Orthotics and Prosthetics Center. This CDAM system aims at shortening the delivery and improving the fit and comfort of custom orthoses and prostheses. The ankle foot orthosis (AFO), a custom made brace that supports muscles and provides control and protection for feet, is selected as an example to demonstrate the CDAM system. Traditionally, custom orthoses are fabricated using plaster molding which requires multiple patient visits and extensive labor and fabrication time. Four key components: 1) the digital scanning of foot and leg geometry using a stand with transparent foot plate and ergonomic procedure for 3D optical scanning, 2) a cloud-based design software that enables clinicians to access scanned point cloud data on the geometry of patients' feet as well as create 3D models for AFOs based on patients' needs, 3) a cloud-based manufacturing software that generates tool paths and process parameters for additive manufacturing to fabricate the AFO, 4) the evaluation using inertia measurement unit (IMU) for measurement of the AFO motion for gait analysis. The feasibility of CDAM system for one-day delivery of AFOs to patients has been demonstrated.