Conclusion

• To achieve the main goal (design and manufacturing of new personalized orthoses) two initial approaches have been used:
• (a) a human upper limb and a human ankle-foot complex were scanned in vivo using Coordinate Measuring Machine “Mitutoyo Euro Apex” and Laser Scanner “Hymare CTD;
• (b) wax models of a human upper limb and a human ankle-foot complex were obtained and after that laser scanned.
• The wax modelling approach demonstrated sufficient surface accuracy and was more comfortable for the patient due to the shorter time for the procedure than in the case of “in vivo” scanning.
• On the base of the scanned data 3D geometrical models of a human upper limb and ankle-foot joint were created and different prototypes were designed in two steps using reverse engineering:
• (a) pre-processing and contours/surfaces fitting (Surfacer™, CopyCAD™ and GeomagicStudio™);
• (b) CAD model reconstruction and evaluation (UniGraphics™ and ProEngineer™).
• The CAD models of the orthoses were analyzed using Finite Element Analysis.
• Layer Manufacturing (Rapid Prototyping) was used to manufacture different polymers prototypes of new Elbow Orthoses and Ankle-Foot Orthoses.
• The results show good perspectives for implementation of the new orthoses in the industry.