3D Segmented Orthoses for Swelling and Joint Mobility
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Solution Overview
Problem
Traditional splints and casts face challenges in accommodating swelling, preventing atrophy, and managing joint stiffness during the healing process, leading to complications such as compartment syndrome, delayed union, and mal-union of fractures.
Innovation Solution
The development of computer-aided design and digital manufacturing techniques to create adaptable exo-skeletal orthoses with semi-dynamic structures that expand or contract in response to swelling and atrophy, incorporating elastic restraints and modular components for controlled pressure application and limited joint mobility, along with integrated sensors for real-time monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a cast is made tightly to provide stable support for healing, then support and stability are improved, but circulation is restricted and compartment syndrome may occur
Solution Approach 1:
The cast incorporates an expandable structure with multiple expandable sections that can dynamically adjust their volume. This allows the cast to transition from a tight-fitting state (providing stability) to an expanded state (relieving pressure), resolving the contradiction between support and circulation.
Solution Approach 2:
The cast is divided into multiple expandable sections separated by expansion joints. Each section can independently expand to accommodate swelling, allowing localized adjustment of pressure while maintaining overall structural support.
2Object-affected harmful factors
If a cast is made loosely to accommodate swelling, then circulation is maintained, but the cast fails to provide stable environment for healing
Solution Approach 1:
The expandable cast structure allows the cast to be initially loose (accommodating swelling and maintaining circulation) and then expanded to a tight-fitting state (providing stability for healing) as needed during the healing process.
Solution Approach 2:
The cast is designed with expandable sections that can be expanded in advance to accommodate expected swelling, then maintained in a stable configuration to provide healing environment, eliminating the need for recasting.
3Shape
If a cast is changed frequently to accommodate swelling and atrophy, then fit is maintained, but patient convenience is reduced and treatment time increases
Solution Approach 1:
The expandable cast can be adjusted in real-time to accommodate changes in anatomy (swelling and atrophy) without requiring removal or replacement. This maintains proper fit throughout the healing process while eliminating the time loss associated with frequent recasting.
Solution Approach 2:
The single expandable cast structure serves multiple functions throughout the healing process: accommodating initial swelling, maintaining fit during atrophy, and providing stable support. This replaces the need for multiple different casts at different stages.
4Strength
If external pressure is applied during hardening to promote bone healing, then bone healing is improved, but the cast becomes too tight and restricts circulation
Solution Approach 1:
The expandable cast structure allows external pressure to be applied during hardening to promote bone healing, then the cast can be expanded afterward to relieve pressure and restore circulation, eliminating the harmful effects while maintaining the beneficial pressure application.
Solution Approach 2:
The cast is designed to accommodate the temporary application of external pressure during hardening, then can be expanded to compensate for the pressure applied, maintaining both healing benefits and circulation.
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
These orthoses effectively manage swelling and atrophy, promote bone healing, prevent joint stiffness, and enhance patient monitoring, thereby reducing complications and improving the efficiency and effectiveness of orthotic interventions.
Implementation Method 1
The segments or cells are assembled with elastic mechanical restraints that hold the segments and cells together and further apply external pressure when a covered body surface undergoes swelling
Data Source
AI summary
A conformable body interface is fabricated using a data set representing a three-dimensional, soft tissue body surface. The conformable body interface includes a body scaffold that is divided into two or more longitudinal segments separated by axial joints. Optionally, the body scaffold is further divided into two or more circumferentially split segments separated by circumferential joints. The axial joints are circumferentially constrained by elastic bands, tabs, or similar structures and the circumferential joints are longitudinally constrained by elastic axial tethers or similar structures. In this way, the body interfaces can accommodate swelling and bending of the body surface.