3D printing orthopedic scoliosis braces: a test comparing FDM with thermoforming
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ORIGINAL ARTICLE
3D printing orthopedic scoliosis braces: a test comparing FDM with thermoforming Davide Felice Redaelli 1 & Valentina Abbate 2,3 & Fabio Alexander Storm 4 & Alfredo Ronca 2 & Andrea Sorrentino 2 & Cristina De Capitani 2 & Emilia Biffi 4 & Luigi Ambrosio 2 & Giorgio Colombo 1 Paolo Fraschini 4
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Received: 18 May 2020 / Accepted: 7 September 2020 / Published online: 15 October 2020 # The Author(s) 2020
Abstract In recent years, 3D printing gained considerable attention in the orthopedic sector. This work evaluates the feasibility of producing orthopedic scoliosis braces by 3D printing, comparing performance and costs with classical thermoforming procedures. Critical parameters, such as manufacture time, mechanical properties, weight, and comfort are carefully considered. Polyethylene terephthalate glycol-modified (PETG) was selected among the several filaments materials present on the market. Printed samples were analyzed with electronic microscope, tensile, and impact tests and compared with thermoformed polyethylene (PE) and polypropylene (PP) samples. Moreover, a cost analysis was carried out for the specific application. The thermoformed brace of a volunteer patient affected by scoliosis was reproduced using reverse-engineering techniques. The model was then printed as a single piece and postprocessed by an expert orthotist. Subsequently, the patient wore the brace in a pilot case to compare comfort and mechanical effectiveness. Results show that the 3D printing fabrication method is able to provide a valid alternative to the current fabrication methods, being also very competitive in terms of costs. The morphological analysis does not show critical defects in 3D printed samples, while the mechanical tests highlighted their anisotropy, with an overall brittleness of PETG samples in the direction orthogonal to the fibers. However, in terms of mechanical stresses, a back brace should never reach the polymer yield stress, otherwise the shape would be modified and the therapeutic effect could be compromised. Finally, the patient reported the perception of improved support and no significant comfort differences compared with the thermoformed brace. Keywords 3D printing . FDM . Manufacturing process . Mechanical characterization . PETG . Orthopedic scoliosis brace Davide Felice Redaelli and Valentina Abbate contributed equally to this work. * Davide Felice Redaelli [email protected]
Emilia Biffi [email protected]
* Giorgio Colombo [email protected]
Luigi Ambrosio [email protected] Paolo Fraschini [email protected]
Valentina Abbate [email protected] Fabio Alexander Storm [email protected] Alfredo Ronca [email protected]
1
Department of Mechanical Engineering, Politecnico di Milano, Via G. La Masa, 1, 20156 Milano (MI), Italy
2
Institute of Polymers, Composites and Biomaterials, National Research Council of Italy, Via Previati 1/C, 23900 Lecco, Italy
3
Department of Chemical, Materials and Industrial Productio
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