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Material Performance Evaluation for Customized Orthoses: Compression, Flexural, and Tensile Tests Combined with
Daniela Trindade1,2,3, Rachel Habiba1,4, Cristiana Fernandes1
1Center for Rapid and Sustainable Product Development (CDRSP), Polytechnic of Leiria, 2430-028 Marinha Grande, Portugal.
Polymers
|September 28, 2024
Summary
Custom 3D-printed orthoses offer improved patient quality of life. Polycarbonate, polylactic acid, and ULTEM™ 1010 show superior performance for durable ankle-foot orthoses fabrication.
Area of Science:
- Biomaterials Engineering
- Orthotics and Prosthetics
- Additive Manufacturing
Background:
- Customized orthoses significantly improve patient quality of life.
- Additive manufacturing (AM), particularly fused deposition modeling (FDM), offers enhanced precision, speed, and comfort in orthotic fabrication.
Purpose of the Study:
- To evaluate the mechanical performance of nine polymeric materials for 3D-printed orthoses.
- To compare material performance based on printing direction (horizontal vs. vertical).
- To identify optimal materials for fabricating durable and high-performing orthoses.
Main Methods:
- Mechanical testing (compressive, flexural, tensile) of nine polymers printed via FDM.
- Comparative analysis of material properties based on printing orientation.
- Finite element modeling (FEM) of an ankle-foot orthosis (AFO) under static load.
Main Results:
- Polycarbonate (PC), polylactic acid (PLA), and ULTEM™ 1010 demonstrated superior mechanical properties.
- These materials exhibited minimal performance variation between horizontal and vertical printing directions.
- FEM simulations indicated favorable deformation, strain, and stress distribution for ULTEM™ 1010.
Conclusions:
- PC, PLA, and ULTEM™ 1010 are highly suitable for 3D-printed orthoses due to their mechanical strength and directional consistency.
- ULTEM™ 1010 is identified as a prime candidate for advanced orthotic fabrication, offering enhanced performance and durability.
- This study provides valuable data for optimizing material selection in custom orthotic device design.
Keywords:
additive manufacturingankle–foot orthosiscustomized orthosesmechanical propertiespolymeric materialsstatic conditionsMore Related Videos
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