CN110897772A - Manufacturing method of ankle-foot orthosis based on 3D printing - Google Patents
Manufacturing method of ankle-foot orthosis based on 3D printing Download PDFInfo
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- CN110897772A CN110897772A CN201911214992.7A CN201911214992A CN110897772A CN 110897772 A CN110897772 A CN 110897772A CN 201911214992 A CN201911214992 A CN 201911214992A CN 110897772 A CN110897772 A CN 110897772A
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F5/00—Orthopaedic methods or devices for non-surgical treatment of bones or joints; Nursing devices; Anti-rape devices
- A61F5/01—Orthopaedic devices, e.g. splints, casts or braces
- A61F5/0102—Orthopaedic devices, e.g. splints, casts or braces specially adapted for correcting deformities of the limbs or for supporting them; Ortheses, e.g. with articulations
- A61F5/0104—Orthopaedic devices, e.g. splints, casts or braces specially adapted for correcting deformities of the limbs or for supporting them; Ortheses, e.g. with articulations without articulation
- A61F5/0111—Orthopaedic devices, e.g. splints, casts or braces specially adapted for correcting deformities of the limbs or for supporting them; Ortheses, e.g. with articulations without articulation for the feet or ankles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
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- Manufacturing & Machinery (AREA)
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- Orthopedic Medicine & Surgery (AREA)
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Abstract
A manufacturing method of an ankle-foot orthosis based on 3D printing comprises the following steps: step 1, adopting plantar pressure data; step 2, scanning the affected limb by using a three-dimensional scanner; step 3, obtaining the point cloud data of the affected limb obtained in the step 2 into an STL file; step 4, performing three-dimensional model digital design on the ankle-foot orthosis structure by using the biomechanics of the ankle-foot, the three-point force system and the abnormal conditions of the sole pressure obtained in the step 1; step 5, topology optimization; step 6, carrying out 3D printing pretreatment to obtain an ankle-foot orthosis with a support; and 7, carrying out post-treatment, adding auxiliary elements such as a liner and a magic tape, and finally fitting the affected limb. The requirements on experience and technology of operators are reduced, meanwhile, the light weight design can be realized, the weight of the ankle-foot orthosis is reduced, and the acceptance degree of a patient on the ankle-foot orthosis is improved.
Description
Technical Field
The invention belongs to the technical field of ankle-foot orthotics, and particularly relates to a manufacturing method of an ankle-foot orthosis based on 3D printing.
Background
A plurality of ankle-foot orthoses for treating ankle-foot disorders such as foot valgus and the like in the prior art are provided. The defects of the prior art are as follows: the plantar pressure of a patient is not tested, and the normal pressure distribution condition and the abnormal distribution condition are analyzed; the method for manufacturing the ankle-foot orthosis by using the traditional plaster has the defects that abundant experience and exquisite manual skill are required for an orthopedic operator, the labor intensity is high, the manufacturing period is long, the manufacturing efficiency is not high, the orthopedic device is too heavy and not attractive, particularly, psychological disorders are large, or children are easy to self-lower when wearing the ankle-foot orthosis, the orthopedic device is often unwilling to wear, and the used materials are too many, so that waste is caused.
Disclosure of Invention
The invention aims to provide a method for manufacturing an ankle-foot orthosis based on 3D printing, so as to solve the problems.
In order to achieve the purpose, the invention adopts the following technical scheme:
a manufacturing method of an ankle-foot orthosis based on 3D printing comprises the following steps:
step 4, importing the STL file obtained in the step three into digital design software, improving a model structure in the software, and performing three-dimensional model digital design on the ankle-foot orthosis structure by utilizing the biomechanics of the ankle-foot, the three-point force system and the abnormal conditions of the sole pressure obtained in the step 1 to improve the stress condition of the ankle-foot;
step 5, carrying out topology optimization on the STL file obtained in the step 4 to obtain an STL model file;
step 6, carrying out 3D printing pretreatment on the STL model file obtained in the step 5 to obtain an ankle-foot orthosis with a support;
and 7, removing the support of the ankle-foot orthosis obtained by SLS in the step 6, performing post-treatment, adding auxiliary elements such as a pad, a magic tape and the like, and finally trying on the affected limb.
Furthermore, during scanning in the step 2, the patient keeps a sitting posture, the affected limb is flatly placed on the flat plate, and the scanning data is ensured to be continuous and complete during scanning.
Further, in step 3, the reverse software is Rhnio; the method comprises the following specific steps:
1) modifying and packaging the point cloud data obtained by scanning in Rhnio, and establishing a complete triangular patch structure model of the scanning part outline;
2) and (3) thickening the triangular plate on the contour surface obtained in the step 1) outwards in Rhnio to generate a shell-shaped three-dimensional model, and storing the shell-shaped three-dimensional model as an STL format file.
Further, in step 4, the digital design software is Creo 3.0.
Further, in step 5, specifically:
the method comprises the steps of firstly carrying out finite element analysis on a model, analyzing the stress of the model, then carrying out topology optimization on the model by using topology optimization software, carrying out treatment such as hollowing and the like, removing redundant structures and reducing the mass of the model.
Further, the topology optimization software is Inspire software.
Further, in step 6, specifically:
importing the three-dimensional model into a Materialise magics21.0, firstly carrying out pretreatment, adding support to the three-dimensional model to obtain a three-dimensional model with a support structure, and adjusting printing parameters to obtain an STL file; the obtained STL file is printed and formed through 3D to obtain an ankle-foot orthosis with a support; the printing of the foot valgus ankle-foot orthosis model adopts a laser sintering forming technology, the 3D printer is a laser sintering curing forming 3D printer, and the used material is nylon.
Further, the post-treatment in the step 7 is sand blasting, shaping and polishing; the magic tape auxiliary structure is an auxiliary bandage which can be adjusted in tightness and fixed.
Compared with the prior art, the invention has the following technical effects:
according to the characteristics of different patients, the pressure distribution of the affected limb of the patient is adjusted by applying the biomechanics of the ankle and foot, the three-point force system and the lower limb anatomy, the design and the manufacture of the ankle and foot orthosis perfectly matching the appearance of the affected limb of the patient are rapidly completed, the using effect of the ankle and foot orthosis is improved, the personalized medical treatment is realized, the requirements on the experience and the technology of operators can be reduced, the lightweight design can be realized, the weight of the ankle and foot orthosis is reduced, and the acceptance degree of the ankle and foot orthosis by the patient is improved.
The concrete points are as follows: the plantar pressure test is carried out on the plantar of a patient, the normal distribution condition and the abnormal distribution condition of pressure can be analyzed, and a foundation is laid for the excellent improvement of the three-dimensional structure of the ankle-foot orthosis; the three-dimensional scanner is used for scanning and accurately forming different symptoms and different appearance characteristics of the affected limb of the patient, so that personalized medical treatment is realized, the high-standard reduction degree of the affected limb is ensured, the ankle-foot orthosis conforming to the appearance of the affected limb of the patient is ensured, and soft tissues are prevented from being injured by compression; compared with the plaster method, the design method of using a computer to carry out digitization can reduce the requirements on experience and technology of operators and can relieve the pain of patients in replacing plaster for many times; by adopting a 3D printing technology, the ankle-foot orthosis can be freely worn, and different materials can be selected to manufacture the ankle-foot orthosis, so that the examination of the recovery degree of the ankle-foot orthosis in the later stage can be observed to a certain extent; when the digital design is carried out, the ankle-foot biomechanics and the three-point force system are used, the three-dimensional structure of the model of the ankle-foot orthosis is improved, the stress condition of the sole of the affected limb of a patient is improved, and the treatment and use effects of the ankle-foot orthosis are improved; by using the 3D printing technology, the manufacturing of the ankle-foot orthosis can be rapidly completed, the model can be subjected to treatment such as hollowing out of the ankle-foot orthosis, the lightweight design is realized, the weight of the ankle-foot orthosis is reduced, the comfort level is high, and the acceptance degree of a patient on the ankle-foot orthosis is improved.
Drawings
FIG. 1 is a process flow diagram of the present invention.
FIG. 2 is a schematic view of the three-point force system of the present invention in the sagittal plane.
Fig. 3 is a schematic diagram of the three-point force system of the present invention in the frontal plane.
FIG. 4 is a diagram of the topology optimization process of the present invention.
Fig. 5 is a schematic view of an upper leg of an ankle-foot orthosis of the present invention.
The three-point force system is illustrated in the sagittal plane schematic diagram: the three point forces control plantar flexion of the ankle joint in the sagittal plane. The three forces are located as follows: 1-first to fifth metatarsal head and toes, upward force; 2-upper part of instep; 3-upper part of calf.
The three-point force system is illustrated in the frontal plane schematic diagram: three forces control the eversion of the ankle joint on the frontal plane. The three forces are located as follows: lateral to heel, inward force; 2-medial malleolus superior, outward force; 3-proximal to the calf, inward force.
Detailed Description
The invention is further described below with reference to the accompanying drawings:
referring to fig. 1 to 5, a method for manufacturing an ankle-foot orthosis based on 3D printing includes the following steps:
step 4, importing the STL file obtained in the step three into digital design software, improving a model structure in the software, and performing three-dimensional model digital design on the ankle-foot orthosis structure by utilizing the biomechanics of the ankle-foot, the three-point force system and the abnormal conditions of the sole pressure obtained in the step 1 to improve the stress condition of the ankle-foot; STL is a file format.
Step 5, carrying out topology optimization on the STL file obtained in the step 4 to obtain an STL model file;
step 6, carrying out 3D printing pretreatment on the STL model file obtained in the step 5 to obtain an ankle-foot orthosis with a support;
and 7, removing the support of the ankle-foot orthosis obtained by SLS in the step 6, performing post-treatment, adding auxiliary elements such as a pad, a magic tape and the like, and finally trying on the affected limb. SLS is selective laser sintering molding.
During scanning in the step 2, the patient keeps sitting posture, the affected limb is flatly placed on the flat plate, and the scanning data is ensured to be continuous and complete during scanning.
In step 3, the reverse software is Rhnio; the method comprises the following specific steps:
1) modifying and packaging the point cloud data obtained by scanning in Rhnio, and establishing a complete triangular patch structure model of the scanning part outline;
2) and (3) thickening the triangular plate on the contour surface obtained in the step 1) outwards in Rhnio to generate a shell-shaped three-dimensional model, and storing the shell-shaped three-dimensional model as an STL format file.
In step 4, the digital design software is Creo 3.0.
In step 5, the method specifically comprises the following steps:
the method comprises the steps of firstly carrying out finite element analysis on a model, analyzing the stress of the model, then carrying out topology optimization on the model by using topology optimization software, carrying out treatment such as hollowing and the like, removing redundant structures and reducing the mass of the model.
The topology optimization software is Inspire software.
In step 6, the method specifically comprises the following steps:
importing the three-dimensional model into a Materialise magics21.0, firstly carrying out pretreatment, adding support to the three-dimensional model to obtain a three-dimensional model with a support structure, and adjusting printing parameters to obtain an STL file; the obtained STL file is printed and formed through 3D to obtain an ankle-foot orthosis with a support; the printing of the foot valgus ankle-foot orthosis model adopts a laser sintering forming technology, the 3D printer is a laser sintering curing forming 3D printer, and the used material is nylon.
Wherein the post-treatment in the step 7 is sand blasting, shape trimming and polishing; the magic tape auxiliary structure is an auxiliary bandage which can be adjusted in tightness and fixed.
As shown in fig. 1, a 3D printing-based digital design and manufacturing method of an ankle-foot orthosis includes the following steps: let the patient walk through the pressure test flat board with the most natural gait, the gait data of gathering is as the reference basis of later analysis and design: obtaining the pressure distribution of the sole of a patient during walking and determining that the pressure distribution of the sole is abnormal;
as shown in fig. 1, in the second step, a Scan three-dimensional scanner is used for scanning the ankle and the calf of the affected limb of the patient to obtain point cloud data of the affected limb model. The patient keeps sitting posture, the affected limb is flatly placed on a flat plate, and the scanning data is ensured to be continuous and complete during scanning without data loss. The dimension scanner has no harm to human body in working process, and has high data acquisition speed.
As shown in fig. 1, step three, importing the point cloud data of the affected limb obtained in step two into reverse software Rhnio for reverse design, and the specific steps are as follows: step 3-1, modifying and packaging the point cloud data obtained by scanning in Rhnio, and building a complete triangular patch structure model of the scanning part outline, and step 3-2, outwardly thickening the triangular patch on the outline surface obtained in the step 3-1 in Rhnio to generate a shell-shaped three-dimensional model, and storing the shell-shaped three-dimensional model as an STL format file. Different appearance characteristics are accurately restored in the reverse process, personalized medical treatment is realized, and the high standard restoration degree of the affected limb is ensured by using computer design; compared with a plaster method, the method for manufacturing the ankle-foot orthosis by using the computer is more efficient, can reduce the requirements on the experience and the technology of operators, can relieve the pain of patients caused by the repeated plaster replacement, and has wide application prospect.
As shown in fig. 1, step four, importing the STL file obtained in step three into Creo 3.0 for digital design, improving a model structure in software, and performing three-dimensional model digital design on the ankle-foot orthosis structure by using the biomechanics of the ankle-foot, the three-point force system and the abnormal conditions of the sole pressure obtained in step one. The stress of the apophyseal point, the pressure pain point and the sensitive point is reduced, the thickness of the corresponding position is reduced, the pressure distribution of the sole is smaller, the stress can be increased by increasing the thickness, and the ankle foot stress condition is improved by utilizing the ankle foot three-point stress principle; ensuring that the basic alignment of the ankle-foot orthosis is normal: in the sagittal frontal plane, the bearing line of the affected limb is ensured to pass through the centers of the hip joint, the knee joint and the ankle joint, and in the sagittal plane, the bearing line of the affected limb is ensured to pass through the center of the knee joint (or the front 10-15 cm) and the center of the ankle joint. By improving the three-dimensional structure of the ankle-foot orthosis, the stress condition of the sole and the load-bearing line of the lower limb are ensured to be normal, and the use effectiveness of the ankle-foot orthosis is effectively improved. This is also a prominent place for the present invention.
As shown in fig. 1, step five, performing finite element analysis and structural topology optimization on the STL file obtained in the step four to ensure the reasonability of the mechanical structure of the ankle-foot orthosis; firstly, carrying out finite element analysis on an ankle-foot orthosis model, and analyzing the stress distribution of the model; and then topology optimization is carried out on the model by using topology optimization software inspire, characteristic processing such as hollowing out, slot adding and the like is carried out, different patients can carry out hollowing out processing in different shapes, redundant structures are removed, the quality of the model is reduced, and the cost is reduced.
Performing 3D printing pretreatment on the STL model file obtained in the fifth step, importing the STL model file into a Materialise magics21.0, performing pretreatment, manually adding support to the three-dimensional model to obtain a supported three-dimensional model, and adjusting printing parameters to obtain the STL file; and (3) carrying out laser sintering molding (SLS) on the obtained STL file to obtain the ankle-foot orthosis with the support.
Removing the support of the ankle-foot orthosis obtained by laser sintering molding (SLS) in the sixth step, and performing post-treatment as shown in the seventh step of fig. 1: the technique of sand blasting, shaping, polishing and the like is added with a liner and a magic auxiliary structure which can adjust the tightness and fix, and finally the ankle-foot orthosis is cleaned to try on the affected limb.
Claims (8)
1. A manufacturing method of an ankle-foot orthosis based on 3D printing is characterized by comprising the following steps:
step 1, a plantar pressure measuring system is adopted to carry out pressure test on the plantar of the affected limb of a patient, so that the plantar pressure distribution of the patient during walking is obtained, and abnormal plantar pressure distribution conditions of different patients are determined;
step 2, scanning the ankle, foot and shank parts of the affected limb by using a three-dimensional scanner to obtain point cloud data of the affected limb;
step 3, importing the point cloud data of the affected limb obtained in the step 2 into reverse software for reverse design to obtain an STL file;
step 4, importing the STL file obtained in the step three into digital design software, improving a model structure in the software, and performing three-dimensional model digital design on the ankle-foot orthosis structure by utilizing the biomechanics of the ankle-foot, the three-point force system and the abnormal conditions of the sole pressure obtained in the step 1 to improve the stress condition of the ankle-foot;
step 5, carrying out topology optimization on the STL file obtained in the step 4 to obtain an STL model file;
step 6, carrying out 3D printing pretreatment on the STL model file obtained in the step 5 to obtain an ankle-foot orthosis with a support;
and 7, removing the support of the ankle-foot orthosis obtained by SLS in the step 6, performing post-treatment, adding auxiliary elements such as a pad, a magic tape and the like, and finally trying on the affected limb.
2. The method for manufacturing the ankle-foot orthosis based on 3D printing according to claim 1, wherein the patient keeps a sitting posture during scanning in step 2, the affected limb is flatly placed on the flat plate, and the scanning data is continuously and completely ensured during scanning.
3. The method for manufacturing the 3D printing-based ankle-foot orthosis according to claim 1, wherein in step 3, the inverse software is Rhnio; the method comprises the following specific steps:
1) modifying and packaging the point cloud data obtained by scanning in Rhnio, and establishing a complete triangular patch structure model of the scanning part outline;
2) and (3) thickening the triangular plate on the contour surface obtained in the step 1) outwards in Rhnio to generate a shell-shaped three-dimensional model, and storing the shell-shaped three-dimensional model as an STL format file.
4. The method for manufacturing an ankle-foot orthosis according to claim 1, wherein the digital design software in step 4 is Creo 3.0.
5. The method for manufacturing the ankle-foot orthosis based on the 3D printing according to the claim 1, wherein the step 5 specifically comprises:
the method comprises the steps of firstly carrying out finite element analysis on a model, analyzing the stress of the model, then carrying out topology optimization on the model by using topology optimization software, carrying out treatment such as hollowing and the like, removing redundant structures and reducing the mass of the model.
6. The method for manufacturing the ankle-foot orthosis based on 3D printing according to claim 5, wherein the topology optimization software is Inspire software.
7. The method for manufacturing the ankle-foot orthosis based on the 3D printing according to the claim 1, wherein in the step 6, the steps are as follows:
importing the three-dimensional model into a Materialise magics21.0, firstly carrying out pretreatment, adding support to the three-dimensional model to obtain a three-dimensional model with a support structure, and adjusting printing parameters to obtain an STL file; the obtained STL file is printed and formed through 3D to obtain an ankle-foot orthosis with a support; the printing of the foot valgus ankle-foot orthosis model adopts a laser sintering forming technology, the 3D printer is a laser sintering curing forming 3D printer, and the used material is nylon.
8. The method for manufacturing an ankle-foot orthosis according to claim 1, wherein the post-processing in step 7 is sand blasting, shaping, and polishing; the magic tape auxiliary structure is an auxiliary bandage which can be adjusted in tightness and fixed.
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Cited By (5)
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| CN113085169A (en) * | 2021-04-01 | 2021-07-09 | 上海酷鹰机器人科技有限公司 | 3D printing forming method of spine corrector |
| CN114191179A (en) * | 2021-12-28 | 2022-03-18 | 中南大学湘雅医院 | Head and neck post-operation conformal pressure-regulating binding device based on 3D printing technology and manufacturing method |
| CN114392020A (en) * | 2022-01-17 | 2022-04-26 | 贵港市人民医院 | Ankle-foot orthosis for children and manufacturing method thereof |
| CN116205090A (en) * | 2023-05-05 | 2023-06-02 | 合肥工业大学 | Method and system for designing bare foot orthosis |
| KR20230085657A (en) * | 2021-12-07 | 2023-06-14 | 대한민국(국립재활원장) | process for ankle foot orthosis using 3D scanning and 3D printing |
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