Thumb abductor orthoses manufactured by additive manufacturing.

Description

/ 8 Thumb abductor orthoses manufactured by additive manufacturing. Field of invention

[001] This patent application pertains to the field of immobilization orthoses, specifically thumb abduction orthoses. The invention consists of a device manufactured by additive manufacturing (3D printing) for the treatment of excessive thumb adduction towards the palmar region. Its main function is to position, fix, and immobilize the thumb in abduction and opposition, allowing the performance of pinch and flexion movements of the hand, promoting the functionality and rehabilitation of the limb. Fundamentals of the invention

[002] Orthoses are devices used in the treatment and rehabilitation of the musculoskeletal system, being applied to a segment of the body to assist or correct limbs or organs with compromised functions. Among the existing types, thumb abduction orthoses stand out, indicated for the treatment of excessive adduction of the thumb towards the palmar region, a condition known as "impacted thumb". This problem usually occurs due to neurological dysfunctions, causing the thumb to remain retracted, limiting its movements and compromising the functionality of the hand. As a consequence, the user faces difficulties in manipulating and holding objects, directly impacting their daily activities.

[003] Thus, the abductor orthosis has the function of keeping the thumb in opposition, allowing the other fingers to perform pinch and flexion movements. The manufacture of this device can be done manually by a specialized professional, using thermoplastic material and considering the individual needs of each patient. Alternatively, production can occur on an industrial scale, with standardized sizes. However, the customization of these devices presents a high cost, due to the manufacturing processes and materials used, which hinders their accessibility for many patients. Petition 870250021634, dated 03 / 19 / 2025, page 13 / 20 / 8

[004] The thumb orthosis models currently available in the state of the art present diverse formal and structural configurations. Among them, there are those that use textile materials in their composition, covering a large part of the hand up to the wrist and whose function is to mobilize the thumb. However, these characteristics can compromise the user's comfort, hindering skin ventilation and making it impossible to use them in activities involving contact with water.

[005] In this context, patent document BR 102022013770-6 stands out, describing an orthopedic thumb brace obtained by shaping, as well as its respective manufacturing process. Although the material used in the aforementioned brace provides a certain level of comfort, its structure is complex, composed of multiple materials, including foam, fabrics, and polymers. This design requires a multi-step manufacturing process, such as cutting, shaping by pressing, and sewing, making production more laborious. In addition, the presented brace has predefined sizes and curves, which limits its adaptation to the anatomical particularities of each user. The high level of complexity in manufacturing also directly impacts the final cost of the product, making its access more restricted.

[006] An alternative for optimizing this type of orthosis is the application of additive manufacturing, a manufacturing process that is increasingly being used in the health sector. This method consists of depositing material in successive layers, allowing greater formal freedom in the construction of complex parts, at a lower cost. This characteristic makes it possible to manufacture customized orthoses, adapted to the specific needs of each user.

[007] Patent document BR 202017023353-2 describes a modular orthosis designed for immobilization of the pelvipodalic region, manufactured by 3D printing with dimensions customized for each patient. The manufacturing process begins with digitizing the patient's anatomy, transforming it into a digital image. The digital model is then adjusted according to the user's measurements and produced by 3D printing using recyclable polymers.

[008] However, the device described in this document is not adaptable to the mobilization needs of the upper limbs. Furthermore, although it presents Petition 870250021634, dated 03 / 19 / 2025, page 14 / 20 / 8 cost reduction compared to conventional methods, its modular structure requires the manufacture of multiple interconnected parts, making the process still expensive. Another limiting factor is the time required for the production and assembly of the orthosis, which prevents its immediate availability to the patient. As a consequence, temporary alternative means are needed for limb mobilization until the device is completed.

[009] Considering the issues described above in the state of the art, the present patent application aims to present a thumb abductor orthosis manufactured by additive manufacturing, specifically by FDM (Fused Deposition Modelling) 3D printing, using PLA (Polylactic Acid) filament.

[010] This orthosis is indicated for the treatment of excessive thumb adduction towards the palmar region, its main functions being to position, stabilize and immobilize the finger in abduction and opposition, allowing the performance of pinch and flexion movements of the hand. The device can be manufactured in two distinct models, called compact and long, both consisting of a single, flat structure. Its manufacturing process is based on the application of heat, allowing the orthosis to be molded directly to the user's hand, ensuring a personalized anatomical fit.

[011] Additionally, the orthosis described in this document has dimensions that allow it to adapt to different hand sizes, ensuring a precise anatomical fit for each user. This versatility is made possible by the material used in its manufacture, PLA (Polylactic Acid) filament, a biodegradable thermoplastic derived from renewable sources, such as starch-rich plants. PLA is characterized by its low resistance to high temperatures, which makes the molding process possible directly on the user's hand, providing an ergonomic and personalized fit.

[012] The present solution also offers a lightweight and simplified design compared to conventional orthoses, providing better skin ventilation and greater user comfort. Furthermore, it stands out for its lower production cost, optimized material use, and reduced manufacturing time. The manufacturing process of this Petition 870250021634, dated 03 / 19 / 2025, page 15 / 20 / 8 orthosis is characterized by an optimized approach, eliminating unnecessary steps and making production more efficient compared to methods described in the state of the art. Brief description of the drawings

[013] In order to aid in understanding the present object, the following figures seek to present the models of thumb abductor orthoses, in greater detail: Figure 1 shows a top view of the compact, flattened model of the thumb abductor orthosis. Figure 2 shows a perspective view of the flattened compact model of the thumb abductor orthosis. Figure 3 shows a perspective view of the compact printed and molded model of the thumb abductor orthosis. Figure 4 shows a front view of the molded compact model being used in a hand. Figure 5 shows the rear view of the molded compact model, being used in a hand. Figure 6 shows a top view of the long, flattened model of the thumb abductor orthosis. Figure 7 shows a perspective view of the long, flattened model of the thumb abductor orthosis. Figure 8 shows the front view of the long printed and molded model of the thumb abductor orthosis. Figure 9 shows the posterior view of the long printed and molded model of the thumb abductor orthosis. Petition 870250021634, dated 03 / 19 / 2025, page 16 / 20 / 8 Figure 10 shows a front view of the molded long model, being used on a hand. Figure 11 shows the rear view of the molded long model, being used on a hand. Figure 12 shows optional manufacturing measurements for the short model of the thumb abductor orthosis. Figure 13 shows optional manufacturing measurements for the short model of the thumb abductor orthosis. Description of the invention

[014] Considering the objective of this request, the following is a detailed description of the thumb abductor orthosis models manufactured by additive manufacturing, called compact and long.

[015] Thumb abductor orthoses are produced from a single flat piece, printed directly onto the 3D printer bed. The surface of the piece displays a triangular pattern, resulting from the slicing process, in which the upper and lower layers are removed to expose the internal filling of the structure, whose density is adjusted to 30%. This pattern is surrounded by a rigid structure along the edges, providing stability and strength to the device. The developed models, called 'compact' and 'long', differ in the length of the rod responsible for fixing the device to the palm of the hand, specifically in the region between the thumb and index finger.

[016] As illustrated in Figures 1, 2 and 3, the compact model has a triangular pattern (1) on its surface, surrounded by a rigid structure along the edges (2). The orthosis is made of a single piece and has, in its upper region, a flap (3) designed to immobilize and enclose the thumb in the proximal phalanx region, positioning it in abduction and opposition. The lower flaps (4) and (5) are designed to fit the user's hand, specifically in the region between the index finger and the thumb, preventing adduction movement of the finger. When molded, the device Petition 870250021634, dated 03 / 19 / 2025, page 17 / 20 / 8 assumes a ring-like configuration, providing a compact and discreet format, Figures 4 and 5.

[017] The long model, represented in Figures 6, 7, 8 and 9, exhibits a triangular pattern (6) on its surface, surrounded by a rigid structure along the edges (7). Like the compact model, it is made of a single piece and has, in the upper region, a flap (8) designed to immobilize and enclose the thumb in the proximal phalanx region, positioning it in abduction and opposition. In the lower part, in addition to a flap (10) similar to that of the compact model, there is an elongated rod (9), developed to replace the use of velcro commonly employed in orthoses of this type. The rod (9) contours the palmar region and attaches to the upper part of the hand, preventing the adduction movement of the thumb, Figures 10 and 11.

[018] The orthosis manufacturing process begins with setting up the digital model file in slicing software, such as Ultimaker Cura. Next, the parameters necessary for 3D printing the orthosis are defined, including removing the top and bottom layers to expose the internal filling, adjusting the filling density to 30%, and applying the triangular pattern. In addition, the printing nozzle temperature is preferably set to 210°C, while the bed temperature is set between 60°C and 70°C. It is noteworthy that no printing support is required.

[019] The file generated in the slicing process is then exported in Gcode format for printing the part using FDM (Fused Deposition Modeling) 3D printing technology with PLA filament. After printing, the orthosis undergoes a molding stage on the end user's hand, using a thermal heater to expose the part to a preferred temperature of 60°C for approximately 30 seconds, or until the material reaches its ideal molding point. During this process, it is recommended to use a thin fabric or similar material to protect the user's skin.

[020] The orthosis is molded as follows: initially, the piece is positioned over the region between the thumb and index finger. In the case of the compact model, the lower tabs (4) and (5) are molded towards the upper part of the palm, while the upper tab (3) surrounds the thumb. In the long model, the tabs (9) and (10) Petition 870250021634, dated 03 / 19 / 2025, page 18 / 20 / 8 are adjusted first, followed by fixing the elongated rod (9) around the thumb. The molding of the tab (3) or the rod (9) around the thumb must be done clockwise, ensuring that its end is positioned on the upper part of the finger, providing a secure and ergonomic fit.

[021] With regard to the dimensions of the orthosis for adults, the short model may optionally have the following measurements: 111 millimeters in length from the distal end of the flap (3) to the end of the lower flap (5); 83 millimeters in total length of the flap (3); 73 millimeters in length between the ends of the lower flaps (4) and (5); and 53 millimeters in width, measured from the lower edge of the lower flap (4) to the upper edge of the flap (3). Figure 12 illustrates these dimensions, noting that other measurements may be adopted according to the specific needs of the patient.

[022] With regard to the dimensions of the orthosis for adults, the long model may optionally have the following measurements: 115 millimeters total length of the elongated rod (9); 83 millimeters length between the ends of the lower flaps (7) and (8); and 55 millimeters width, measured from the lower edge of the rod (9) to the upper edge of the flap (8). Figure 13 illustrates these dimensions, noting that other measurements may be adopted according to the specific needs of the patient. Examples of embodiments of the invention

[023] The present invention, referred to as a thumb abductor orthosis manufactured by additive manufacturing, has a wide range of applications within the area of ​​health and rehabilitation, such as in use in Physiotherapeutic Rehabilitation, assisting in the functional recovery of the thumb in patients with injuries such as dislocations, fractures, tendinitis and other conditions that affect the mobility of the joint.

[024] In the field of neurology, the present invention can be applied to patients with motor impairment resulting from neurological diseases, such as stroke, cerebral palsy, and neuromuscular pathologies, providing support and stabilization of the joint. Other noteworthy fields of application for the present invention are pediatrics and geriatrics, where the orthosis can be adapted for use in children with special needs and Petition 870250021634, dated 03 / 19 / 2025, page 19 / 20 / 8 elderly people who have loss of mobility in their hands, assisting in maintaining functionality and performing daily activities.

[025] As assistive technology, orthotics can contribute to the development of ergonomic devices for individuals with difficulties in gripping and fine motor coordination, providing greater hand functionality, greater ease of movement, and independence in daily activities. Regarding the 3D printing industry for healthcare, orthotics, in their various models, enable customized manufacturing through additive manufacturing technology, allowing on-demand production for clinics, hospitals, and healthcare professionals, reducing costs and optimizing manufacturing time.

[026] It should be mentioned that the applications described here do not limit the scope of usability of the present invention, but only exemplify areas of possible applications.

[027] In view of the foregoing, the present invention offers an innovative solution for the immobilization and stabilization of the thumb, combining ergonomics, comfort and practicality. Its additive manufacturing process allows the device to be customized according to the user's needs, ensuring a precise and efficient fit. Furthermore, its wide applicability in various areas of health and assistive technology reinforces its relevance as an accessible and effective alternative for rehabilitation and functional support. Thus, the invention represents a significant advance in the field of orthotics, providing benefits for both patients and healthcare professionals. Petition 870250021634, dated 03 / 19 / 2025, page 20 / 20

Claims

1 / 2 CLAIMS 1. THUMB ABDUCTOR ORTHOSES MANUFACTURED BY ADDITIVE MANUFACTURING, characterized by being constituted of a single flat piece, produced in PLA (Polylactic Acid) filament by means of 3D printing; where the surface of the orthosis presents a triangular pattern, surrounded by a rigid structure along the edges; the present invention can also be developed in two distinct models: compact and long.

2. THUMB ABDUCTOR ORTHOSES MANUFACTURED BY ADDITIVE MANUFACTURING, according to claim 1, characterized by the compact model having an upper flap (3) and two lower flaps (4) and (5), configuring, after molding, an annular structure; optionally having, for the version intended for adults, the following dimensions: 111 millimeters in length from the distal end of the flap (3) to the end of the lower flap (5); 83 millimeters in total length of the flap (3); 73 millimeters in length between the ends of the lower flaps (4) and (5); and 53 millimeters in width, measured from the lower edge of the lower flap (4) to the upper edge of the flap (3).

3. THUMB ABDUCTOR ORTHOSES MANUFACTURED BY ADDITIVE MANUFACTURING, according to claim 1, characterized by the long model having a flap (8) in the upper region, and also having, in its lower portion, a flap (10) and an elongated rod (9); optionally having, for the version intended for adults, the following dimensions: 115 millimeters of total length of the elongated rod (9); 83 millimeters of length between the ends of the lower flaps (7) and (8); and 55 millimeters of width, measured from the lower edge of the rod (9) to the upper edge of the flap (8).

4. THUMB ABDUCTOR ORTHOSES MANUFACTURED BY ADDITIVE MANUFACTURING, characterized by its manufacturing process beginning with the configuration of the digital model file in slicing software, such as Ultimaker Cura, where the parameters necessary for Petition 870250021634, dated 03 / 19 / 2025, page 1, are then defined.10 / 20 2 / 2 3D printing of the orthosis, including the removal of the top and bottom layers to expose the internal filling, adjustment of the filling density to 30%, and application of the triangular pattern; the printing nozzle temperature is preferably set to 210°C, while the bed temperature is set between 60°C and 70°C, with no need for a printing support; sequentially, the file generated in the slicing process is then exported in G-code format for printing the part using FDM (Fused Deposition Modeling) 3D printing technology with PLA filament; after printing, the orthosis undergoes a molding stage on the end user's hand, using a thermal heater to expose the part to a preferred temperature of 60°C for approximately 30 seconds, or until the material reaches its ideal molding point, with the use of a thin fabric or similar material recommended to protect the user's skin.

5. THUMB ABDUCTOR ORTHOSES MANUFACTURED BY ADDITIVE MANUFACTURING, according to claim 4, characterized in that the molding of the orthosis occurs as follows: initially, the piece is positioned over the region between the thumb and index finger, with, in the case of the compact model, the lower tabs (4) and (5) molded towards the upper part of the palm of the hand, while the upper tab (3) surrounds the thumb; in the long model, the tabs (9) and (10) are adjusted first, followed by the fixation of the elongated rod (9) around the thumb, finally, the molding of the tab (3) or the rod (9) around the thumb must be performed in a clockwise direction. Petition 870250021634, dated 03 / 19 / 2025, page 11 / 20

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