Improvement of ankle foot orthotics fabrication using 3D printing method

Kushendarsyah Saptaji; Dinda Arina Manasikana; Octarina Adiati Juniasih; Mochammad Rafli Ramadhani; Muchamad Oktaviandri; Anwar Ilmar Ramadhan; Yuli Panca Asmara

doi:10.22441/sinergi.2024.3.015

Authors

Kushendarsyah Saptaji Mechanical Engineering Department, Faculty of Engineering and Technology, Sampoerna University, Indonesia
Dinda Arina Manasikana Mechanical Engineering Department, Faculty of Engineering and Technology, Sampoerna University, Indonesia
Octarina Adiati Juniasih Department of Mechanical Engineering, Sepuluh Nopember Institute of Technology, Indonesia
Mochammad Rafli Ramadhani Mechanical Engineering Department, Faculty of Engineering and Technology, Sampoerna University, Indonesia
Muchamad Oktaviandri Department of Mechanical Engineering, Universitas Pembangunan Nasional Veteran, Indonesia
Anwar Ilmar Ramadhan Department of Mechanical Engineering, Universitas Muhammadiyah Jakarta, Indonesia
Yuli Panca Asmara Faculty of Engineering and Quantity Surveying, INTI International University, Malaysia

DOI:

https://doi.org/10.22441/sinergi.2024.3.015

Keywords:

3D scanning, 3D printing, Ankle-foot orthotics (AFO), Gait Cycle, Photogrammetry,

Abstract

Orthotics are the body support devices used for correction, immobilization, fixation, and prevention of paralysis. The greatest number of orthotics utilized by people suffering from plantarflexion and dorsiflexion disability, especially in Indonesia, is ankle foot orthotic (AFO). However, the duration associated with fabricating AFO through conventional methods is considered time-consuming. This paper aims to fabricate ankle foot orthotics (AFO) using innovative combinations of 3D scanning and 3D printing. The method begins with 3D scanning of the patient’s lower limb using photogrammetry (3DF Zephyr). The design is generated and adjusted, afterwards, the orthotic prototype is produced by fused deposition modeling (FDM) 3D printing using polypropylene (PP) material. This choice is attributed to the material's advantages, such as being lightweight, rigid, durable, and cost-effective. The 3D mesh model scanned using 3DF Zephyr shows good quality and more precise results. In addition, the prototype produced using 3D printing was tested by walking based on normal gait analysis’s angle of foot and calf measurement, which shows a maximum range of motion (ROM) of 16.1˚. The proposed methods of fabricating orthotic prototypes can successfully reduce the processing time by approximately 70% compared to the conventional method.