A new design approach for customised medical devices realized by additive manufacturing
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ORIGINAL PAPER
A new design approach for customised medical devices realized by additive manufacturing V. Ricotta1 · R. I. Campbell2 · T. Ingrassia1
· V. Nigrelli1
Received: 14 May 2020 / Accepted: 28 August 2020 © The Author(s) 2020
Abstract The aim of this work is the design of a new customised elbow orthosis completely realized by Additive Manufacturing and the development of generative algorithms for parametric modelling and creation of 3D patterns to be adapted to the CAD model. This work describes a method to perfect the design of a custom elbow orthosis. A reverse engineering approach has been used to digitalize the patient’s arm and the subsequent CAD modelling of the structure of the custom elbow orthosis has been performed. In particular, two algorithms have been implemented for the creation of 3D patterns and Voronoi tessellations. Subsequently, FEM analyses have been carried out to validate the design. Finally, a prototype of the elbow orthosis with Voronoi tessellation has been realized by means of the SLS technology. The results obtained have demonstrated that the implemented algorithm solved the problems found during CAD modelling with conventional software. Furthermore, the results of FEM analyses have validated the design choices. All this allowed realizing the prototype by AM technologies without problems. Moreover, the new proposed modelling approaches allows creating, in an interactive way, patterns on complex surfaces. The results of this research activity present innovative elements of originality in the CAD modelling sector, which can contribute to solving problems related to the modelling for Additive Manufacturing. Furthermore, another innovative characteristic of the device is the use of torsion springs that simulate the action of physiotherapists during exercises for patient rehabilitation. Keywords Reverse engineering · Additive manufacturing · Generative design · Computer aided design · Elbow orthosis
1 Introduction Orthoses are medical devices that help people with disabilities. Orthoses support, align, prevent or correct deformities and improve the joint function with the purpose of improving the users’ quality of life. For patients with disabilities that contribute to functional limitations, orthoses are used to apply forces on the body for biomechanical needs [1–3]. Orthoses can be divided into two main categories: the nonarticular and the articular. The articulated orthoses permit an adjustment during their use while the non-articulated are the ones which have only one possible configuration and, consequently, do not allow a regulation during their use [4]. Moreover, orthoses can be customised, adapting better to
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T. Ingrassia [email protected]
1
Dipartimento di Ingegneria, Università degli Studi di Palermo, Viale delle Scienze, 90128 Palermo, Italy
2
Loughborough Design School, Loughborough University, Loughborough LE11 3TU, UK
the patient’s body than the prefabricated devices and ensuring better performances [5–7]. The fitness of orthoses is the most importa
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