Research on Design and Topology Optimization of Personalized Scoliosis Orthopedic Device

The incidence of adolescent idiopathic scoliosis (AIS) is on the rise. Clinically, conservative treatment usually involves wearing spinal orthoses. However, traditional orthoses are bulky, which adversely affects patient tolerance and quality of life. Therefore, the development of personalized, lightweight spinal orthoses that also take into account mechanical performance holds significant practical value. Based on 3D-scanned trunk data, the designs of the iliac crest, three-point force application areas, and relief zones are completed through deviation analysis and X-ray-model registration. A finite element model is established to simulate the mechanical responses under two states: wearing the orthosis and applying an opening force. By comparing four material removal rate schemes, the "50% material removal scheme" is identified as the optimal initial-stage scheme. Based on the optimization results, the left iliac crest is further selected as the optimization area for secondary topological optimization. The results show that the secondary topological optimization achieves an additional 6.7% weight reduction compared to the "50% material removal scheme," resulting in a total weight reduction of 41.6%. The maximum stress is 46.63 MPa, and the maximum deformation in the orthotic region is 0.74 mm, both of which meet the design requirements. This study provides a reference for the lightweight design of spinal orthoses for patients with specific types of scoliosis.