Applying 3D Scanning and Printing Technologies in the Custom Design of Foot Orthoses

ABSTRACT This paper presents the development of a passive, non‐articulated foot orthosis by integrating 3D scanning and 3D printing technologies, following a comprehensive analysis of existing orthotic solutions available on the market. The proposed methodology begins with the precise capture of the foot's anatomical geometry through 3D scanning, enabling a customized fit and enhanced user comfort. The acquired data is then processed in specialized 3D modeling software to generate a digital orthosis model, which is subsequently fabricated using additive manufacturing. This workflow offers an efficient and cost‐effective approach to producing personalized orthopedic devices. The final physical prototype shall be tested, in future studies, by a user to assess both the geometric fit and comfort level during ambulation. The results underscore the potential of combining 3D scanning, CAD modeling, and 3D printing in the development of customized orthopedic solutions, emphasizing the advantages of personalization, rapid prototyping, and reduced production time. Future studies are intended to evaluate the structural performance of the design; the digital model might undergo Finite Element Analysis (FEA) under simulated loading conditions corresponding to normal walking dynamics. This paper aims to conduct a thorough study of existing ankle‐foot orthoses, as well as to create such an orthosis using 3D scanning and 3D printing, and to perform a biomechanical analysis on the final prototype.