3D-Printed Orthotic Shell With Variable Thickness for Foot Stress Distribution

Solution Overview

Problem

Conventional orthotic devices lack customization to accommodate individual anatomical variations, leading to inadequate support and stress distribution for patients with unique foot structures, such as valgus or varus deformities.

Innovation Solution

An orthotic device with a shell of variable thickness, manufactured using additive manufacturing, which is designed to conform to the patient's foot anatomy, providing targeted support and flexibility through a digital scanning and 3D printing process, allowing for customized geometry and thickness adjustments to alleviate stress and improve fit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional orthotic devices use uniform thickness design, then manufacturing is simple, but they cannot accommodate individual anatomical variations and provide inadequate support

Engineering Contradiction:

Improveaccommodation of anatomical variationsVSAvoidvariable thickness design

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The orthotic device employs variable thickness design where different regions of the shell have different thicknesses to provide customized support. The shell thickness is increased in areas requiring higher structural support (such as arch and heel regions) and reduced in areas requiring flexibility, thereby accommodating individual anatomical variations while maintaining manufacturing feasibility through additive manufacturing processes

Inventive Principle:

Principle #3Local quality

2Reliability

If orthotic devices are customized to fit individual foot anatomy, then support and stress distribution improve, but manufacturing complexity increases

Engineering Contradiction:

Improvestress distributionVSAvoidcustomized manufacturing

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention utilizes additive manufacturing technology to produce orthotic devices with variable shell thickness based on digital models of individual patient anatomy. The manufacturing process allows precise control of material deposition to achieve the desired thickness profile, enabling customization without significantly increasing manufacturing complexity. The digital modeling and layer-by-layer construction facilitate accurate stress distribution while maintaining ease of production

Inventive Principle:

Principle #35Parameter changes

3Strength

If the shell thickness is increased in areas of increased stress, then structural support improves, but the device becomes heavier

Engineering Contradiction:

Improvestructural supportVSAvoidorthotic device weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The orthotic device employs variable thickness design where different regions of the shell have different thicknesses to provide customized support. The shell thickness is increased in areas requiring higher structural support (such as arch and heel regions) and reduced in areas requiring flexibility, thereby accommodating individual anatomical variations while maintaining manufacturing feasibility through additive manufacturing processes

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20220183871A1Additive manufacturing techniques for orthotics

Publication Date: 2022.06.16 HANGER INC

AI summary

An orthotic device for a patient's foot includes a shell that is configured to structurally support the patient's foot. The shell has a variable thickness along a dimension of the shell. The shell is configured to undergo flexion throughout the shell. The variable thickness of the shell targets areas of increased stress.