Design and Development of a Flexible and Reusable Neck Orthosis Using Thermoplastic Polyurethane

This research presents the design of a flexible and reusable neck orthosis using Thermoplastic Polyurethane (TPU). Traditional cervical collars often face challenges such as poor ventilation, generalized sizing, odor retention, and reduced stiffness after washing. This study aimed to address these issues by creating a custom-fitted orthosis that enhances patient comfort and support. The design, created using CATIA software, incorporated an elliptical hole pattern to improve flexibility and breathability while maintaining structural integrity with a reduced thickness of 3.5 mm. Finite Element Analysis (FEA) was performed using ANSYS software to assess the mechanical behavior of the orthosis under various load conditions (40N, 60N, 80N, and 100N). The results showed that stress was effectively distributed, with the highest concentrations at the upper side edges of the model. Mechanical properties, including equivalent stress, maximum shear stress, total deformation, and equivalent elastic strain, were evaluated, demonstrating the orthosis's capability to withstand significant forces while maintaining flexibility. The study concludes that the developed neck orthosis offers a promising alternative to conventional collars by addressing critical issues of comfort, breathability, and durability. These findings support the potential for additive manufacturing in producing custom-fitted, patient-specific orthotic devices that improve clinical outcomes and patient satisfaction.