CN215307118U

CN215307118U - Ankle-foot orthosis based on 3D printing

Info

Publication number: CN215307118U
Application number: CN202121807723.4U
Authority: CN
Inventors: 马致远; 王影; 马睿佳; 彭宇
Original assignee: First Affiliated Hospital of Medical College of Xian Jiaotong University; National Institute Corp of Additive Manufacturing Xian
Current assignee: First Affiliated Hospital of Medical College of Xian Jiaotong University; National Institute Corp of Additive Manufacturing Xian
Priority date: 2021-08-04
Filing date: 2021-08-04
Publication date: 2021-12-28
Anticipated expiration: 2031-08-04

Abstract

The utility model discloses an ankle-foot orthosis based on 3D printing, which is structurally divided into three parts: the ankle joint comprises a lower leg part, an achilles tendon part and a sole part, wherein the attaching part of the lower leg part is attached to the rear side and the side surface of the lower leg, the achilles tendon part is attached to the rear side and the side surface of the ankle, and the sole part is attached to the bottom and the side of the foot; the ankle is arranged outside the whole ankle-foot orthosis; the stress concentration parts outside the crus part and the achilles tendon part are provided with Y-shaped reinforcing structures together, and the orthosis adopting the Y-shaped structure has the advantages of good fitting degree, light weight, high strength and good protection. The pair of orthotics is convenient to penetrate into shoes and boots of patients, the problem that the existing orthotics are not attached enough, the desire that the physiology and the psychology of the patients are integrated into the society is achieved, and the gait of the patients suffering from the stroke is greatly improved.

Description

Ankle-foot orthosis based on 3D printing

Technical Field

The utility model belongs to the technical field of medical rehabilitation instruments, and particularly relates to an ankle-foot orthosis based on 3D printing.

Background

With the development of science and technology and the rapid development of 3D printing, three-dimensional scanning and reverse engineering are further popularized. And the reverse design is simple by combining the application of industrial three-dimensional software and the product development of the reverse design. The method provides a good development momentum for the research, development and application of a customized 3D printing orthosis, carries out basic mechanical analysis of the orthosis by combining the existing mechanical analysis, combines the orthopedic experience of a traditional orthopedic operator and a gait analyzer, carries out scheme design by a doctor and the orthopedic operator according to the gait of a patient, provides possibility for the precision, customization and comfort of the patient, but is limited by the 3D printing process and the material problem, so that the customized orthosis has certain limitations, and the mechanical performance of the orthosis is defective due to the limitation of the material and the process. On the other hand, the existing ankle-foot orthosis has long manufacturing period and complicated mould removal, is difficult to fit different patients, and has certain influence on the rehabilitation of the patients.

SUMMERY OF THE UTILITY MODEL

The utility model aims to overcome the defects of the prior art and provide an ankle-foot orthosis based on 3D printing to solve the problem that the existing ankle-foot orthosis is difficult to fit each patient and limit the movement of the patient.

In order to achieve the purpose, the utility model adopts the following technical scheme to realize the purpose:

an ankle-foot orthosis based on 3D printing, comprising a lower leg part, an achilles tendon part and a plantar part which are integrally connected from bottom to bottom; the lower leg part is attached to the back side and the side surface of the lower leg, the achilles tendon part is attached to the back side and the side surface of the ankle, and the foot bottom part is attached to the bottom and the side part of the foot; the ankle is arranged outside the whole ankle-foot orthosis;

the outer parts of the lower leg part and the achilles tendon part are provided with a Y-shaped reinforcing structure together, the upper end of the Y-shaped reinforcing structure is arranged on the outer part of the lower leg part, and the lower end of the Y-shaped reinforcing structure is arranged on the outer part of the achilles tendon part.

The utility model is further improved in that:

preferably, the height of the Y-shaped reinforcing structure is 1/4-1/3 of the sum of the heights of the lower leg part and the achilles tendon part.

Preferably, the Y-shaped reinforcing structure comprises a rear supporting part and two side supporting parts, the rear ends of the two side supporting parts are connected with the upper end of the rear supporting part together, and the front ends of the two side supporting parts are arranged on the two sides of the shank part respectively; the height of the front end of the side supporting part is higher than that of the rear end of the side supporting part; the lower end of the rear support part is arranged outside the Achilles tendon part.

Preferably, the front portion of the sole portion is inclined upwardly by 10-30 ° with respect to the horizontal.

Preferably, the rear part of the lower leg part is provided with a lightening hole.

Preferably, the front end of each side of the lower leg part is provided with an upper connecting part and a lower connecting part, and the upper connecting part is arranged above the lower connecting part; the upper end of the side edge of the sole part is provided with a bottom connecting part;

the front end of each upper connecting part and the front end of each lower connecting part are provided with connecting holes; the upper end of each bottom connecting part is provided with a connecting hole.

Compared with the prior art, the utility model has the following beneficial effects:

Furthermore, the height of the Y-shaped reinforcing structure is limited, and the Y-shaped reinforcing structure is guaranteed not to limit the movement of a patient due to overhigh strength while playing a supporting role.

Further, the Y-shaped reinforcing structure comprises a rear support and two side supports, and the supporting performance can be improved.

Furthermore, the front part of the sole part inclines upwards relative to the horizontal plane and is bound by a bandage at the thumb part, so that the phenomenon that the patient orthopedic device penetrates into the shoe and the orthopedic device is not attached to the foot, the orthopedic device is not attached to the shoe and the like can be prevented.

Furthermore, a lightening hole is formed in the rear portion of the lower leg portion, and the weight of the whole orthosis is reduced.

Furthermore, the front side of the achilles tendon part is provided with a connecting hole, and the whole device can be arranged on the foot of a patient through the magic tape.

Drawings

FIG. 1 is a schematic view of the bones of the foot of a human body structure;

FIG. 2 is a rear view of an ankle-foot orthosis of the present invention;

FIG. 3 is a side view of an ankle-foot orthosis of the present invention;

FIG. 4 is a schematic diagram of a curved edge design according to the present invention;

FIG. 5 is a simulation of a surface design;

(a) the figure is a right side view, and the figure (b) is a left side view.

FIG. 6 is a side view of a raw leg portion of example 1;

FIG. 7 is a front elevation view of a thigh section of example 1;

FIG. 8 is a top view of a worn ankle-foot orthosis;

FIG. 9 is a side view of the ankle-foot orthosis being worn;

FIG. 10 is a mechanical simulation of the wearing of an ankle-foot orthosis;

wherein: 1-the calf part; 2-achilles tendon portion; 3-the plantar part; 4-Y type reinforcing structure; 4-1-rear supporting part; 4-2-side supporting part; 5-an upper linking moiety; 6-lower connecting moiety; 7-a bottom connecting part; 8-lightening holes.

Detailed Description

The utility model is described in further detail below with reference to the accompanying drawings:

the front, back, up and down described below all depend on the front, back, up and down of a normal human body, as shown in fig. 1, the description of the present invention all depends on the reference, and the description is not repeated.

The utility model discloses an ankle-foot orthosis based on 3D printing and a manufacturing method thereof, and the ankle-foot orthosis specifically comprises the following steps:

step 1, aiming at the problems that a stroke patient cannot lift legs or leg lifting is prone to foot varus and foot valgus, a good leg model cannot be scanned and obtained, and final alignment of an orthosis cannot be referred, so that the patient is initially required to be in a correct sitting posture to scan leg data of the patient; when a patient is in a sitting posture, the middle point of the ankle joint, the middle point of the knee joint and the middle point of the hip joint are required to be in the same force line, leg data are obtained, and digital-analog reference is provided for later-stage design and alignment of an orthosis.

And 2, respectively scanning the knees and the following data by using a three-dimensional scanner according to the natural standing posture of the patient after the patient is straightened, wearing a flesh-colored elastic sock for the patient in the scanning process, facilitating and quickly scanning, avoiding the problem that dead corners are difficult to scan, and providing convenience for the inverse image of a later model if gaps of toes are difficult to scan. A three-dimensional scanner obtains data, including specifically the size and shape, of the patient's lower leg, ankle, and foot, as shown in fig. 6 and 7.

And 3, importing the leg data of the patient obtained in the step two into the geomagic for data processing to obtain a complete STL model of the leg of the patient.

And 4, importing the STL model of the sitting leg of the patient obtained in the step 3 into Rhino, and performing inverse image modeling on the leg of the patient by using an rhinoceros plug-in T-spline to obtain the editable CAD three-dimensional solid curved surface model of the leg of the patient. Cutting the three-dimensional curved surface, removing curved surfaces above a longitudinal arch curve 5 in the cutting process, removing curved surfaces before a calcaneus at the ankle as shown in fig. 1, exposing an ankle joint outside the three-dimensional curved surface, vertically extending upwards along curves at two sides of the curved surface at the ankle, extending to the lower part of a knee, removing the curved surfaces before the curves at two sides of the curved surface, and obtaining a single curved surface of the ankle-foot orthosis as shown in fig. 4, wherein the edge part of the single curved surface is the edge part of the target ankle-foot orthosis, a black line as shown in fig. 4 is a cutting line, and a longitudinal arch curve is a curve between the middle of a first metatarsal and the calcaneus; then, an upper connecting part 5 and a lower connecting part extend from the front ends of the two side parts of the single curved surface, the front part of each side is provided with the upper connecting part 5 and the connecting part 6, and the front end of each connecting part is also provided with a connecting hole. And a bottom connecting hole 7 is formed in each side of the upper ends of two sides of the bottom of the single curved surface.

As one preferable scheme, the proper loose adjustment is carried out for 1-2mm according to the ankle, the foot root and the terminal parts of the first metatarsal bone and the fifth metatarsal bone, so that the discomfort caused by the compression of the foot root, the metatarsal bone and the ankle of the patient is avoided.

Step 5, expanding the size of the whole by 2m to make the thickness of the lining out, thickening the whole by 3mm outwards with the deflected curved surface to obtain an orthosis which is not provided with a reinforcing structure in the first stage, wherein the basic body is 2-3mm, preferably 3mm, and obtaining a curved surface basic body;

further, the lifting process aims at the toe inner buckling problem of the patient. A doctor determines the lifting angle of an orthosis at the toe stepping part of a patient according to the gait analysis of the patient, and the bandage restriction of the thumb part is combined to prevent the three non-sticking phenomena that the orthosis of the patient is penetrated into a shoe and the orthosis is not stuck to the foot, the orthosis is not stuck to the shoe and the like. Referring specifically to fig. 3, the angle α between the distal end of the first phalangeal joint to the front end of the foot and the horizontal plane, α, is 10-15 °.

Step 6, leading the curved surface basic body out of the STL, leading the curved surface basic body into ansys for mechanical analysis, according to a mechanical distribution diagram obtained by the obtained mechanical analysis, aiming at a place with concentrated stress and large stress (as shown in figure 10), aiming at the walking requirement of a patient, twisting of an ankle joint needs certain activity, so that the activity limitation on the left and right of the structure of the achilles tendon reinforcing part needs to be reduced, determining the specific position of the Y-shaped structure, generally the position is positioned at the heel tendon of the human body and the upper part thereof, therefore, the Y-shaped reinforcing structure 4 is arranged at the part, when the specific design is carried out, according to the size of the leg of the patient, the position and the size of the Y-shaped reinforcing structure 4 can be correspondingly adjusted, but the total size cannot exceed 1/3 from the sole to the length of the lower part of the knee, the rear supporting part 4-1 of the Y-shaped reinforcing structure 4 is positioned on the central line of the calf bone, the side supporting part 4-2 extends forwards along the curved surface of the muscle, and the prepared Y-shaped reinforcing structure 4 can be used for properly supporting the muscle of the leg.

The process of obtaining the Y-shaped reinforcing structure 4 specifically comprises the steps that the Y-shaped reinforcing structure 4 copies the back side face of a curved surface basic body to obtain a copied curved surface, the copied surface is moved to the right back of the curved surface basic body, the copied curved surface is cut according to the shape and the size of the Y-shaped reinforcing structure 4 to obtain the outer surface of the Y-shaped reinforcing structure 4, the space between the outer surface of the Y-shaped reinforcing structure 4 and the back side face of the Y-shaped reinforcing structure 4 is thickened to obtain the Y-shaped reinforcing structure 4, and a model with the Y-shaped reinforcing structure 4 is obtained; as shown in fig. 5;

step 7, outputting the STL model with the Y-shaped reinforcing structure 4 to a laser sintering, curing and forming 3D printer, and printing the STL model by adopting slicing treatment on the STL model through the laser sintering, curing and forming 3D printer by using magics software, wherein the STL model is made of nylon PA12 powder

Step 8, obtaining the orthosis through SLS printing, wherein the obtained ankle-foot orthosis is rough, performing aftertreatment polishing on the orthosis, and polishing the orthosis to be smooth so as to prevent certain rough parts from wearing shoes of patients and prevent linings from being adhered or falling off due to roughness in certain places, and finally, dressing of the orthosis is affected. After polishing, the lining is stuck and the bandage is bound, and the patient is put on the bandage.

The orthosis is designed according to different leg thicknesses of different patients, different foot types and different ankle fat-thin parts through reverse design based on the scanning of the affected limb of a scanning patient. The mechanical analysis is carried out through anysys software, corresponding structural reinforcement is carried out on the part with large stress concentration, the most appropriate reinforced torsion structure is made according to a large amount of experimental data, and the control force is too strong at the structure part when the ankle-foot orthosis is worn and broken by some 3D printing.

Further, the nylon material has insufficient strength in combination with the sls PA12 process. A reinforcing structure is needed to ensure that the nylon does not break when applied to an ankle-foot orthosis.

Referring to fig. 2 and 3, the structure of the prepared 3D printing-based ankle-foot orthosis specifically comprises a lower leg part 1, an achilles tendon part 2 and a sole part 3 which are integrally connected from bottom to bottom; the lower leg part 1 is attached to the back side and the side surface of the lower leg, the achilles tendon part 2 is attached to the back side and the side surface of the ankle, and the foot bottom part 3 is attached to the bottom and the side part of the foot; the three parts are integrated for printing and supporting, have no boundary line and are divided into three parts for convenient description. Preferably, the sum of the heights of the lower leg part 1 and the achilles tendon part 2 is 360-380mm, and as can be seen from the figure, the lower leg part 1 and the achilles tendon part 2 can completely wrap the rear part of the lower leg and the achilles tendon of the patient, and a small amount of edges extend out of the side surface; the plantar portion 3 also completely envelops the bottom of the foot, with the sides extending up to the edges. The front part of each side of the side edge extending out of the lower leg part 1 is provided with an upper connecting part 5 and a connecting part 6, and the front end of each connecting part is also provided with a connecting hole. And a bottom connecting hole 7 is formed in each side of the upper ends of two sides of the bottom of the single curved surface. The ankle sets up in the outside of whole ankle foot orthopedic ware, can remove ankle bone when making things convenient for the patient to walk about, and this structure passes through Y type additional strengthening when enough supporting of department based on stress concentration, can not inject the removal of ankle bone, promotes patient's use impression.

The outer parts of the lower leg part and the achilles tendon part are provided with a Y-shaped reinforcing structure together, the upper end of the Y-shaped reinforcing structure is arranged on the outer part of the lower leg part, and the lower end of the Y-shaped reinforcing structure is arranged on the outer part of the achilles tendon part. The height of the Y-shaped reinforcing structure is 1/4-1/3 of the sum of the heights of the calf portion 1 and the achilles tendon portion 2.

Referring to fig. 3, the Y-shaped reinforcing structure 4 comprises a rear supporting part 4-1 and two side supporting parts 4-2, the rear ends of the two side supporting parts 4-2 are connected with the upper end of the rear supporting part 4-1, and the front ends of the two side supporting parts 4-2 are respectively arranged at the two sides of the shank part 1; the height of the front end of the side supporting part 4-2 is higher than that of the rear end of the side supporting part 4-2; the lower end of the rear support 4-1 is disposed outside the Achilles tendon portion 2. The two side supporting parts 4-2 extend upwards along the two sides of the muscle, so that the better fitting degree is ensured.

The front part of the sole portion 3 is inclined upwards by 10-30 deg. in relation to the horizontal plane, see the range of 10-30 deg. for alpha in fig. 3.

The rear part of the shank part 1 is provided with a plurality of lightening holes 8, the lightening holes 8 are arranged at the stress-unconcentrated part of the shank, the supporting effect of the whole orthosis is not influenced, the weight can be lightened, and the ventilation property is good.

This is further described below in conjunction with specific examples.

Examples

Referring to figures 6 and 7 for specific dimensions of a patient's leg, the height of the calf is 446.74mm (calf part 1 and achilles tendon part), the foot length is 269.70mm, and the foot width is 96.66 mm. Referring to fig. 8 and 9, the model was made with a total height of the Y-shaped reinforcing structure 4 of 12cm, a total width of the Y-shaped curve of 6-8 mm, a height of the whole orthosis, i.e., a height from an upper end of the calf portion to a lower end of the achilles portion of 380.83mm, and a width of the widest portion of the plantar portion 3 of 96.66 mm.

In the preparation process, the bottom part is located at the joint of the heel part of the patient and the Achilles tendon, and is 12cm above the Achilles tendon part. And cutting the copied surface with the thickness of 3mm, and performing Y-shaped curved surface cutting. The thickness of the cut Y-shaped curved surface is increased by 2 m.

The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the utility model, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.

Claims

1. An ankle-foot orthosis based on 3D printing, characterized by comprising a lower leg part (1), an achilles tendon part (2) and a sole part (3) which are integrally connected from bottom to bottom; the lower leg part (1) is attached to the back side and the side surface of the lower leg, the achilles tendon part (2) is attached to the back side and the side surface of the ankle, and the sole part (3) is attached to the bottom and the side part of the foot; the ankle is arranged outside the whole ankle-foot orthosis;

the outer parts of the lower leg part (1) and the achilles tendon part (2) are provided with a Y-shaped reinforcing structure (4) together, the upper end of the Y-shaped reinforcing structure (4) is arranged on the outer part of the lower leg part (1), and the lower end of the Y-shaped reinforcing structure (4) is arranged on the outer part of the achilles tendon part (2).

2. An ankle-foot orthosis according to claim 1, based on 3D printing, characterized in that the height of the Y-shaped stiffening structure is 1/4-1/3 of the sum of the heights of the lower leg part (1) and the achilles tendon part (2).

3. 3D-print based ankle-foot orthosis according to claim 1, characterized in that the Y-shaped reinforcing structure (4) comprises a rear support (4-1) and two side supports (4-2), the rear ends of the two side supports (4-2) being jointly connected to the upper end of the rear support (4-1), the front ends of the two side supports (4-2) being arranged on either side of the lower leg part (1).

4. The 3D print-based ankle-foot orthosis according to claim 3, characterized in that the height of the front end of the side support (4-2) is higher than the height of the rear end of the side support (4-2); the lower end of the rear supporting part (4-1) is arranged outside the Achilles tendon part (2).

5. 3D-print based ankle-foot orthosis according to claim 1, characterized in that the front part of the sole part (3) is inclined upwards by 10 ° -30 ° relative to the horizontal plane.

6. 3D-print based ankle-foot orthosis according to claim 1, characterized in that the rear part of the lower leg part (1) is provided with lightening holes (8).

7. An ankle-foot orthosis according to claim 1, characterized in that the front end of each side of the lower leg part (1) is provided with an upper connecting part (5) and a lower connecting part (6), the upper connecting part (5) being above the lower connecting part (6); the upper end of the side edge of the sole part (3) is provided with a bottom connecting part (7).

8. The 3D print-based ankle-foot orthosis according to claim 7, characterized in that the front end of each of the upper connecting part (5) and the lower connecting part (6) is provided with a connecting hole; the upper end of each bottom connecting part (7) is provided with a connecting hole.