Development and Customization of a Dennis Brown Orthosis Prototype Produced from Anthropometric Measurements by Additive Manufacturing

Congenital clubfoot is an orthopedic manifestation characterized by poor alignment of the foot as deformities in equine and varus of the hindfoot, cavus and adduction in the middle and forefoot. The Dennis Brown Orthosis is part of the final phase of the treatment of pathology in children. This research presents the development of a prototype of Dennis Brown Orthosis by additive manufacture, with experimental observational character to enhance production performance and viability. Methodology: The research was divided into four phases: 1. 3D modeling of the Dennis Brown orthosis based on anthropometric measurements of a positive infant foot cast of plaster and digital file; 2. Analysis of the mechanical structure of the orthosis by computational simulation with the finite element method; 3. Production of orthosis by additive manufacture with 3D desktop printer Anet A8 and polylactic acid material (PLA); 4. Study of the technical and financial feasibility of the use of the manufacturing methodology adopted. Results: A prototype of Dennis Brown children's orthosis customized was manufactured with digital equipment and the cost was nearly to the commercial model of orthosis made in orthopedic in a handmade way. In addition to lowering costs, the model produced by 3D printing has advantages of minimizing production time and reducing material waste. In addition, because it is manufactured through a digital file, the procedure can be done from 3D scanning without molding the child's foot with plaster, and the production procedure can be repeated as many times as necessary. Conclusion: The research presented feasibility from the technical and financial point of view of the application of additive manufacturing in the process of making a prototype of Dennis Brown Orthosis. In the next phase of the research, clinical evaluations will be carried out with volunteers.