Application of 3D Scanning Techniques, CAD/CAE Modeling and 3D Printing, in the Development of Customized Ankle and Foot Orthoses

Objective: To develop a prototype of a custom ankle and foot orthosis using 3D scanning, CAD/CAE systems and rapid prototyping, evaluating ABS and PLA materials under specific loads. Theoretical Framework: Innovation in custom orthoses is based on advances in 3D scanning, virtual model processing, and 3D printing, to obtain ergonomic and durable devices. Method: Using a digital model by 3D scanning, a solid model was built using a CAD/CAE system, which allowed comparing its response in terms of strength and deformation for ABS and PLA materials, under loads of patients of different weights. Results and Discussion: Both materials showed good response: PLA offered rigidity and stability, ideal for immobility; ABS, flexibility and impact resistance, suitable for fluctuating loads. Research Implications: This study suggests that both materials are viable for custom orthoses. In addition, it proposes evaluating composite materials that combine the qualities of ABS and PLA. Originality/Value: This research is original in exploring alternative materials for orthoses through additive manufacturing and offers value to the rehabilitation sector by proposing personalized orthoses according to the characteristics of the patient, improving the effectiveness and durability in mobility treatments.