Cushioned Orthotic Shell With Integral Discrete Elements
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Solution Overview
Problem
The current manufacturing process of orthotic and prosthetic devices is labor-intensive, time-consuming, and prone to variations due to manual craftsmanship, leading to delays and inconsistencies in the final product, despite some advancements in computer-assisted design and rapid prototyping, which still require significant manual intervention and equipment.
Innovation Solution
The integration of a cushioning structure with discrete solid and resilient elements that can be adjusted and formed in an integral manner with the orthotic or prosthetic shell, allowing for customizable cushioning properties and reduced manual intervention through computer-aided design and rapid prototyping, enabling precise adaptation of cushioning properties across different areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual manufacturing processes are used for orthotic and prosthetic devices, then customization and craftsmanship quality can be achieved, but the process becomes labor-intensive, time-consuming, and prone to variations
Solution Approach 1:
The manufacturing process is divided into distinct digital and physical stages: digital scanning of the limb, CAD design of the device including cushioning elements, and rapid prototyping fabrication. This segmentation allows each stage to be optimized independently, eliminating manual rework and ensuring consistency between design intent and final product.
Solution Approach 2:
Manual mechanical processes (plaster casting, manual shaping, hand-laying cushioning materials) are replaced with digital scanning, computer-aided design, and automated rapid prototyping systems. This substitution eliminates human variability and significantly reduces production time while maintaining or improving precision.
2Productivity
If computer-assisted design and rapid prototyping are used, then production time can be reduced, but significant manual intervention and specialist equipment are still required
Solution Approach 1:
The design and manufacturing processes are merged into an integrated digital workflow where the CAD model directly drives the rapid prototyping fabrication. The cushioning elements are designed as integral parts of the device geometry, eliminating separate manual assembly steps and reducing the need for specialist manual intervention.
Solution Approach 2:
The rapid prototyping system serves multiple functions: it fabricates both the structural shell and the cushioning elements in a single process. This multi-functionality reduces the need for separate specialist equipment and manual operations for different components.
3Adaptability or versatility
If cushioning materials are added manually during finishing, then local modifications can be made, but the process is time-consuming and creates variations in quality
Solution Approach 1:
The cushioning elements are designed and fabricated as integral parts of the device during the rapid prototyping stage, before final assembly. This preliminary action eliminates the need for time-consuming manual addition of cushioning materials during finishing, while still allowing full customization based on patient-specific requirements captured in the CAD design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in more consistent and customizable orthotic and prosthetic devices with improved cushioning performance, reduced production time, and less waste, while allowing for patient-specific designs and easier adjustments, enhancing both quality and efficiency in manufacturing.
Implementation Method 1
The purpose of cushioning is to absorb the forces placed on it through compression or elastic or plastic deformation of the cushioning material
Implementation Method 2
The purpose of cushioning is to absorb the forces placed on it through compression or elastic or plastic deformation of the cushioning material
Data Source
AI summary
Orthotic and prosthetic devices having integrated features such as cushioning features are described, as well as methods for computer aided designing and making of these devices. The orthotic or prosthetic devices comprise a cushioning layer superimposed onto an orthotic or prosthetic shell, the cushioning layer comprising an array (35) of discrete solid and resilient cushioning elements (31). In one preferred embodiment, the cushioning structure is a beam, defined around a centerline of any arbitrary shape. In another preferred embodiment, the cushioning structure has the shape of a spiral.