Enhancing 3D Printed Bed-Resting Ankle-Foot Orthosis Design through Topology Optimization

Ankle-foot orthoses (AFOs) are devices used to support patients with ankle muscle weakness from conditions like stroke or cerebral palsy. This project designs a lightweight AFO for bedridden patients, focusing on engaging the calf muscle and enhancing structural performance while minimizing material use through topology optimization using CAD software, Solid Works. The study analyzed three materials: Polylactic Acid (PLA), Nylon 6, and Acrylonitrile Butadiene Styrene (ABS). Weight reduction was assessed using Cura software, dividing the AFO into foot and shank models with specific loading and boundary conditions. Five levels of topology optimization (10%-50% weight reduction) were proposed, showing similar weight reduction patterns across materials. However, while weight was reduced, filament usage and printing time were not, as the optimized models required additional support elements during printing. Thus, topology optimization reduces the product's weight but not necessarily filament usage in 3D printing.