Design and development of a modular ankle foot orthosis with the aid of additive manufacturing
Lower limb muscle weakness is a common symptom in many
neuromuscular conditions and traumatic injuries, often leading to
abnormal gait, instability, and reduced mobility. Ankle-foot orthoses
(AFOs) are widely prescribed to support functional walking, yet current
production methods remain labor-intensive, poorly adjustable, and limited
in their ability to accommodate evolving user needs. This thesis explores
the design and development of a modular, patient-specific AFO using
additive manufacturing (AM), in collaboration with Materialise and
Materialise Motion.
The project follows an adapted Stanford Biodesign methodology,
incorporating clinical research, user feedback, and iterative engineering
across three phases: Identify, Invent, and Develop. By reframing the
design process to account for technical, clinical, and experiential
demands, the resulting AFO aims to better align with the real-world needs
of orthotists and patients. The core innovation lies in a three-part modular
architecture: ankle-cuff, strut, and footplate, each optimized for digital
fabrication and individualized stiffness tuning.
To support this modularity, a parametric CAD workflow and Finite Element
Analysis (FEA) were used to iteratively tune the geometry and stiffness of
individual components. Physical testing under physiological loads
confirmed the reliability of the design, while patient and expert input
reinforced the importance of comfort, fit, and ease of use.
This thesis demonstrates the potential of AM to move beyond cosmetic
customization and deliver functional, adaptable orthoses. While further
clinical validation is required, the proposed system offers a promising step
toward more personalized and efficient orthotic care.
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