Ankle Foot Orthotics Optimization by Means of Composite Reinforcement of Free-Form Structures

Ankle-Foot-Orthoses (AFOs) are assistive devices prescribed for a number of physical and neurological disorders affecting the mobility of the lower limbs. Traditional AFO design is based on thermoforming polymer sheets around a plaster cast with a characteristic stiffness depending on the selected trim-line with the inherent design limitations. Additive Manufacturing has been explored as an alternative process; however it has proved to be inefficient cost-wise. This work explores the possibilities of generating modular AFO elements: calf, shank, and footplate with localized composite reinforcement that aids in the optimization of the device in terms of functionality, aesthetics, rigidity and cost.