Custom Orthosis Manufacturing Using 3D Scanning and Additive Printing

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Solution Overview

Problem

Conventional methods for manufacturing custom orthoses and prostheses are labor-intensive and time-consuming, requiring weeks or months to complete, which can leave individuals without the necessary devices for an extended period.

Innovation Solution

The process involves generating a three-dimensional digital model of a body part using scanning or digitizing techniques, followed by additive manufacturing to produce customized orthoses or prostheses, allowing for rapid production and incorporation of multiple materials with varying properties to achieve tailored rigidity and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional casting and molding methods are used to manufacture custom orthoses and prostheses, then customization and fit quality are improved, but production time and labor intensity increase significantly

Engineering Contradiction:

Improvecustomization precisionVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent uses digital scanning to create a precise digital copy of the patient's body part, which is then used to generate the custom device design. This digital copying eliminates the need for physical casting and manual molding, dramatically reducing production time while maintaining customization precision. The digital model can be directly used for additive manufacturing, bypassing traditional time-consuming physical model creation steps.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces manual mechanical processes (casting, molding, hand-sculpting) with computerized systems. Digital scanning replaces physical casting, CAD software replaces manual design, and additive manufacturing replaces traditional molding. This substitution of mechanical systems with computational ones reduces both production time and labor intensity while preserving customization capabilities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If traditional manual manufacturing processes are used, then device quality and customization are maintained, but productivity and output speed decrease

Engineering Contradiction:

Improvedevice qualityVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent changes the fundamental parameters of the manufacturing process by transitioning from batch manual production to digital additive manufacturing. This enables precise control over material deposition parameters, layer thickness, and manufacturing speed, allowing high-quality custom devices to be produced much faster than traditional methods. The digital control parameters ensure consistent quality while dramatically increasing productivity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes additive manufacturing's ability to incorporate multiple materials with different properties within a single device. This allows for composite structures that optimize both quality and performance, with different regions having different material properties as needed. The layered deposition process inherent in additive manufacturing naturally creates composite structures that can be produced efficiently at scale.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If custom devices are manufactured individually using conventional methods, then patient-specific fit is achieved, but manufacturing complexity and resource consumption increase

Engineering Contradiction:

Improvepatient-specific customizationVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent creates a universal digital workflow that can handle any custom orthosis or prosthesis case. The same digital scanning, CAD design, and additive manufacturing process can be applied to different body parts and device types, standardizing the manufacturing process while maintaining full customization capability. This universal approach reduces process complexity compared to having separate manual procedures for each device type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent performs digital scanning and design work before actual manufacturing begins. The digital model and manufacturing instructions are prepared in advance, allowing the additive manufacturing process to proceed directly without intermediate steps. This preliminary digital preparation simplifies the physical manufacturing process while maintaining patient-specific customization.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11478365B2Use of additive manufacturing processes in the manufacture of custom wearable and/or implantable medical devices

Publication Date: 2022.10.25 3D PATENTS LLC

AI summary

A method for manufacturing a custom wearable and/or implantable medical device, such as an orthosis (e.g., an ankle brace, etc.), a prosthesis or the like, includes use of scanning processes. A digital model of a surface may be applied to a digital device model to define a custom digital device model. The digital model and, thus, the custom digital device model may include one or more standard features. The custom digital device model may be used with an automated manufacturing process to make some or all of the custom wearable and/or implantable medical device. In some embodiments, additive manufacturing processes may be used to form a portion or all of the custom wearable and/or implantable medical device.