Preliminary evaluation of an additive manufacturing procedure for producing patient-specific upper-limb orthotic devices

In the orthopedic field, the need for patient-specific devices is crucial to ensure a rapid and successful care treatment. The traditional techniques for manufacturing customized orthopedic systems, specifically orthoses, are laborious and present multiple and time-consuming steps. The present research analyzed the possibility of optimizing the conventional process for manufacturing personalized orthoses by leveraging the principles of Reverse Engineering (RE) and Additive Manufacturing (AM). Digital orthotic models of different anatomical regions were obtained using 3D laser scanning and semi-automated CAD processing, whilst, the prototypes were produced using a Fused Deposition Modelling (FDM) printer and polymeric filaments suitable for the intended use. Furthermore, topological optimization was employed to improve the shape and the weight of the different medical devices. Potential advantages and drawbacks of the discussed procedure were evaluated through a preliminary indication of production times and costs.