Orthopedic Support Element Overlap Production via 3D Mold Casting
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Solution Overview
Problem
Existing methods for producing orthopedic support elements, such as the rolling and conventional molding methods, are limited in size and complexity, leading to issues with edge length constraints, material deaeration, and sagging, making it difficult to create large or complex orthoses like those for the torso, and require significant manual labor and complex mold production.
Innovation Solution
A method using a casting mold with an inner and outer mold, where the outer mold surrounds the overlapping portion on both sides, allowing for greater design freedom and precise production of orthopedic support elements with an overlapping region that can completely cover body parts, using digital and 3D printing techniques to create molds and cast silicone materials effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the rolling method is used to produce orthopedic support elements, then the production process is relatively simple, but the edge length is constrained and cannot be used for large orthoses
Solution Approach 1:
The production process is divided into multiple sequential rolling operations. The orthotic device is produced in sections, with each rolling operation covering a specific portion. The material is rolled sequentially to extend the effective edge length beyond the limitations of a single rolling operation, enabling production of large orthoses while maintaining the simplicity of the rolling method.
2Reliability
If manual deaeration is performed by puncturing gas bubbles on the roller, then the material can be degassed, but the process becomes particularly complex
Solution Approach 1:
A vacuum chamber is introduced as an intermediary device to perform deaeration. The rolled material is placed in the vacuum chamber where reduced pressure causes gas bubbles to rise and be removed from the material. This automated vacuum deaeration process replaces the complex manual puncturing method, maintaining effective gas removal while significantly reducing process complexity and manual intervention.
3Loss of time
If silicone is deposited before reaching the end of its pot life, then the material can be applied, but it sags and runs visibly
Solution Approach 1:
The silicone material is prepared and positioned in advance within a mold or support structure before the end of its pot life. The mold provides immediate structural support that prevents sagging and running. By pre-positioning the material in its final configuration with supportive fixtures in place, the material maintains its shape throughout the remaining pot life and during the vulcanization process, eliminating sagging issues.
4Manufacturing precision
If the conventional molding method is used, then orthopedic support elements can be produced, but the production of casting molds is complex and requires high proportion of manual work
Solution Approach 1:
Instead of creating complex custom casting molds for each orthosis, the invention uses 3D scanning to create a digital copy of the patient's body part. This digital model is then used to generate the orthosis design and guide the rolling production process. The digital copy replaces the need for physical casting molds, eliminating the complex mold production step while maintaining the ability to produce precise, customized orthopedic support elements.
5Productivity
If the rolling method is used, then production can be performed, but it cannot be used for orthopedic support elements with overlapping portions
Solution Approach 1:
The invention transitions from a two-dimensional rolling process to a three-dimensional construction approach using multiple layers. Overlapping portions are achieved by rolling separate sections of the orthosis with overlaps, then bonding them together to form a three-dimensional structure. This multi-layer construction method enables the production of orthopedic support elements with overlapping portions while maintaining the productivity benefits of the rolling process.
Data Source
AI summary
The present invention relates to a method for producing an orthopaedic support element (1) having an overlap portion (2) in which the orthopaedic support element overlaps itself when it is applied to a body part that is to be corrected, wherein a manufacturing configuration (25) of the orthopaedic support element (1) is predefined for the production thereof, which manufacturing configuration (25) deviates from a therapy configuration (26) of the orthopaedic support element (1) when applying the latter to the body part that is to be corrected, wherein in the manufacturing configuration (25), in the overlap portion (2), a spacing (24) exists between a first open end (22) and the second open end (23) of the orthopaedic support element (1), which spacing (24) is not present in the therapy configuration (26).