A Comparative Analysis between Conventional Manufacturing and Additive Manufacturing of Ankle-Foot Orthosis
Article Sidebar
Published:
Apr 13, 2020
Keywords:
3D print Additive manufacturing Ankle-Foot Orthosis Conventional manufacturing Fused deposition modelling Selective laser sintering
Main Article Content
Abstract
3D printing has been attracting attention in recent years due to its versatility in design optimization and reduced labour and production costs. It has been implemented in many major sectors such as automotive, aerospace, and healthcare. One of the most recent researches involving this technology is in the prosthetics and orthotics field. The aim of this paper is to review the recent researches on Ankle-Foot Orthosis (AFO) which uses 3D printing in its manufacturing and fabrication phase. This paper discusses the current 3D printing technologies used for AFO, the comparison between Conventional Manufacturing (CM) and Additive Manufacturing (AM) of AFO, as well as the mechanical properties of AFO prototypes built from 3D printing. Results from this review show that most current researches use Fused Deposition Modelling (FDM) or Selective Laser Sintering (SLS) for AFO manufacturing, and the materials used are mostly thermoplastics such as Nylon and Polyamide (PA). The results also show that the tensile strength and Young’s Modulus of a 3D-printed AFO could reach as high as 43 MPa and 3.9 GPa, respectively. It can be concluded that 3D printing provides wider opportunities in the development of AFO due to its versatility in optimizing complex geometries, time and weight savings, as well as its cost-effectiveness.
Article Details
How to Cite
Shahar, F. S., Hameed Sultan, M. T., Md Shah, A. U., & Azrie Safri, S. N. (2020). A Comparative Analysis between Conventional Manufacturing and Additive Manufacturing of Ankle-Foot Orthosis. Applied Science and Engineering Progress, 13(2), 96–103. Retrieved from https://ph02.tci-thaijo.org/index.php/ijast/article/view/240576
Issue
Section
Research Articles
References
[1] F. S. Shahar, M. T. Hameed Sultan, S. H. Lee, M. Jawaid, A. U. Md Shah, S. N. A. Safri, and P. N. Sivasankaran, “A review on the orthotics and prosthetics and the potential of kenaf composites as alternative materials for ankle-foot orthosis,” Journal of the Mechanical Behavior of Biomedical Materials, vol. 99, pp. 169–185, 2019.
[2] L. K. Kian, N. Saba, M. Jawaid, and M. T. H. Sultan, “A review on processing techniques of bast fibers nanocellulose and its polylactic acid (PLA) nanocomposites,” International Journal of Biological Macromolecules, vol. 121, pp. 1314– 1328, 2019.
[3] N. H. Mostafa, Z. N. Ismarrubie, S. M. Sapuan, and M. T. H. Sultan, “Effect of equi-biaxially fabric prestressing on the tensile performance of woven E-glass/polyester reinforced composites,” Journal of Composite Materials, vol. 50, no. 24, pp. 3385–3393, 2016.
[4] M. T. H. Sultan, K. Worden, W. J. Staszewski, S. G. Pierce, J. M. Duliue-Barton, and A. Hodzic, “Impact damage detection and quantification in CFRP laminates: A precursor to machine learning,” in Proceedings 7th International Workshop on Structural Health Monitoring, 2009, vol. 2, pp. 1528–1537.
[5] T. Khan, M. T. B. Hameed Sultan, and A. H. Ariffin, “The challenges of natural fiber in manufacturing, material selection, and technology application: A review,” Journal of Reinforced Plastics and Composites, vol. 37, no. 11, pp. 770–779, 2018.
[6] S. D. Salman, Z. Leman, M. T. H. Sultan, M. R. Ishak, and F. Cardona, “The effects of orientation on the mechanical and morphological properties of woven kenaf-reinforced poly vinyl butyral film,” BioResources, vol. 11, no. 1, pp. 1176– 1188, 2016.
[7] M. J. Sharba, Z. Leman, M. T. H. Sultan, M. R. Ishak, and M. A. A. Hanim, “Tensile and compressive properties of woven kenaf/glass sandwich hybrid composites,” International Journal of Polymer Science, vol. 2016, pp. 1–6, 2016.
[8] S. D. Salman, Z. Leman, M. T. H. Sultan, M. R. Ishak, and F. Cardona, “Kenaf/synthetic and Kevlar®/cellulosic fiber-reinforced hybrid composites: A review,” BioResources, vol. 10, no. 4, pp. 8580–8603, 2015.
[9] S. S. Chee, M. Jawaid, M. T. H. Sultan, O. Y. Alothman, and L. C. Abdullah, “Thermomechanical and dynamic mechanical properties of bamboo/woven kenaf mat reinforced epoxy hybrid composites,” Composites Part B: Engineering, vol. 163, pp. 165– 174, 2019.
[10] A. F. M. Nor, M. T. H. Sultan, M. Jawaid, A. M. R. Azmi, and A. U. M. Shah, “Analysing impact properties of CNT filled bamboo/glass hybrid nanocomposites through drop-weight impact testing, UWPI and compression-after-impact behaviour,” Composites Part B: Engineering, vol. 168, pp. 166–174, 2019.
[11] S. D. Salman, Z. Leman, M. T. H. Sultan, M. R. Ishak, and F. Cardona, “Effect of kenaf fibers on trauma penetration depth and ballistic impact resistance for laminated composites,” Textile Research Journal, vol. 87, no. 17, pp. 2051–2065, 2017.
[12] P. Zakikhani, R. Zahari, M. T. H. Sultan, and D. L. Majid, “Thermal degradation of four bamboo species,” BioResources, vol. 11, no. 1, pp. 414– 425, 2016.
[13] Y. G. T. Girijappa, S. M. Rangappa, J. Parameswaranpillai, and S. Siengchin, “Natural fibers as sustainable and renewable resource for development of eco-friendly composites: A comprehensive review,” Frontiers in Materials, vol. 6, pp. 1–14, 2019.
[14] DE Editors, “Transforming Ankle Foot Orthosis with 3D Printing - Digital Engineering,” 2017. [Online]. Available: http://www.digitaleng.news/de/transforming-ankle-foot-orthosis-3d-printing/
[15] M. Walbran, K. Turner, and A. J. McDaid, “Customized 3D printed ankle-foot orthosis with adaptable carbon fibre composite spring joint,” Cogent Engineering, vol. 3, no. 1, pp. 1–11, 2016.
[16] Y. H. Cha, K. H. Lee, H. J. Ryu, I. W. Joo, A. Seo, D. H. Kim, and S. J. Kim, “Ankle-foot orthosis made by 3D printing technique and automated design software,” Applied Bionics and Biomechanics, vol. 2017, pp. 1–6, 2017.
[17] J. P. Deckers, M. Vermandel, J. Geldhof, E. Vasiliauskaite, M. Forward, and F. Plasschaert, “Development and clinical evaluation of lasersintered ankle foot orthoses,” Plastics Rubber and Composites, vol. 47, no. 1, pp. 42–46, 2018.
[18] L. Aydin and S. Kucuk, “A method for more accurate FEA results on a medical device developed by 3D technologies,” Polymers for Advanced Technologies, vol. 29, no. 8, pp. 2281–2286, 2018.
[19] E. Vasiliauskaite, A. Ielapi, M. D. Beule, W. V. Paepegem, J. P. Deckers, M. Vermandel, M. Forward, and F. Plasschaert, “A study on the efficacy of AFO stiffness prescriptions,” Disability and Rehabilitation: Assistive Technology, to be published, doi: 10.1080/17483107.2019.1629114.
[20] S. S. Bobby, S. Narayanan, and A. K. Nath, “A study on the strength of sintered part in SLS process by infiltration technique,” KMUTNB International Journal of Applied Science and Technology, vol. 5, no. 1, pp. 1–10, 2012.
[21] A. Chen, “Detail comparison of 3D printing methods: SLS vs FDM & SLA vs DLP,” 2019. [Online]. Available: https://www.cmac.com.au/blog/3d-printing-methods-side-by-side-comparisonsls- vs-fdm-sla-vs-dlp
[22] R. K. Chen, L. Chen, B. L. Tai, Y. Wang, A. J. Shih, and J. Wensman, “Additive manufacturing of personalized ankle-foot orthosis,” Transactions of the North American Manufacturing Research Institution of SME, vol. 42, pp. 381–389, 2014.
[23] Curbell Plastics, “ALL MATERIALS,” 2020. [Online]. Available: https://www.curbellplastics.com/Shop-Materials/All-Materials/#?Shape= CRBL.SkuSheet
[24] S. Dickins and T. Jarrott, “Head to foot ortho. catalogue august 2017,” 2020. [Online]. Available: https://www.htforthotics.com.au/images/documents/ HTFO Catalogue Rev 8 Web.pdf
[25] Pathway Pedorthic Footcare, “Pricing for Basic Services,” 2020. [Online]. Available: https:// www.pathwaypedorthicfootcare.com/pricing
[26] H. Watkin, “Father 3D Prints Orthoses for his Son, Now Helps Others,” 2018. [Online]. Available: https://all3dp.com/father-3d-prints-orthoses-sonnow-helps-others-company-nimake/
[27] Truity, “Orthotist or Prosthetist,” 2019. [Online]. Available: https://www.truity.com/career-profile/ orthotist-or-prosthetist
[28] ICRC, Manufacturing Guidelines Ankle-Foot Orthosis. International Committee of the Red Cross, Geneva, Switzerland, 2010.
[29] B. Goldschmidt, “3D Printer Material Cost – The Real Cost of 3D Printing Materials,” 2019. [Online]. Available: https://all3dp.com/2/3d-printer-materialcost-the-real-cost-of-3d-printing-materials/
[30] J. Flynt, “How Much Does 3D Printing Filament Cost?,” 2017. [Online]. Available: https:// 3dinsider.com/3d-printing-filament-cost/
[31] J. W. Gooch, “Tensile Strength at Yield,” 2011. [Online]. Available: https://omnexus. specialchem.com/polymer-properties/properties/strength-at-yield-tensile
[32] G. Hill, “Young’s Modulus,” 2019. [Online]. Available: https://omnexus.specialchem.com/ polymer-properties/properties/young-modulus
[33] R. M. Kumar, N. Rajini, T. S. M. Kumar, K. Mayandi, S. Siengchin, and S. O. Ismail, “Thermal and structural characterization of acrylonitrile butadiene styrene (ABS) copolymer blended with polytetrafluoroethylene (PTFE) particulate composite,” Materials Research Express, vol. 6, no. 8, pp. 1–6, 2019.
[34] L. Techawinyutham, S. Siengchin, R. Dangtungee, and J. Parameswaranpillai, “Influence of accelerated weathering on the thermo-mechanical, antibacterial, and rheological properties of polylactic acid incorporated with porous silica-containing varying amount of capsicum oleoresin,” Composites Part B: Engineering, vol. 175, pp. 1–8, 2019.
[35] B. Nim, P. Sreearunothai, P. Opaprakasit, and A. Petchsuk, “Preparation and properties of electrospun fibers of titanium dioxide-loaded polylactide/polyvinylpyrrolidone blends,” Applied Science and Engineering Progress, vol. 12, no. 1, pp. 52–58, 2019.
[36] S. Phongtamrug, P. Phakpharin, S. Soontaranon, and S. Rugmai, “Structural investigation of poly (lactic acid) cast film by using synchrotron X-ray scattering technique,” KMUTNB: International Journal of Applied Science and Technology, vol. 11, no. 2, pp. 151–155, 2018.
[2] L. K. Kian, N. Saba, M. Jawaid, and M. T. H. Sultan, “A review on processing techniques of bast fibers nanocellulose and its polylactic acid (PLA) nanocomposites,” International Journal of Biological Macromolecules, vol. 121, pp. 1314– 1328, 2019.
[3] N. H. Mostafa, Z. N. Ismarrubie, S. M. Sapuan, and M. T. H. Sultan, “Effect of equi-biaxially fabric prestressing on the tensile performance of woven E-glass/polyester reinforced composites,” Journal of Composite Materials, vol. 50, no. 24, pp. 3385–3393, 2016.
[4] M. T. H. Sultan, K. Worden, W. J. Staszewski, S. G. Pierce, J. M. Duliue-Barton, and A. Hodzic, “Impact damage detection and quantification in CFRP laminates: A precursor to machine learning,” in Proceedings 7th International Workshop on Structural Health Monitoring, 2009, vol. 2, pp. 1528–1537.
[5] T. Khan, M. T. B. Hameed Sultan, and A. H. Ariffin, “The challenges of natural fiber in manufacturing, material selection, and technology application: A review,” Journal of Reinforced Plastics and Composites, vol. 37, no. 11, pp. 770–779, 2018.
[6] S. D. Salman, Z. Leman, M. T. H. Sultan, M. R. Ishak, and F. Cardona, “The effects of orientation on the mechanical and morphological properties of woven kenaf-reinforced poly vinyl butyral film,” BioResources, vol. 11, no. 1, pp. 1176– 1188, 2016.
[7] M. J. Sharba, Z. Leman, M. T. H. Sultan, M. R. Ishak, and M. A. A. Hanim, “Tensile and compressive properties of woven kenaf/glass sandwich hybrid composites,” International Journal of Polymer Science, vol. 2016, pp. 1–6, 2016.
[8] S. D. Salman, Z. Leman, M. T. H. Sultan, M. R. Ishak, and F. Cardona, “Kenaf/synthetic and Kevlar®/cellulosic fiber-reinforced hybrid composites: A review,” BioResources, vol. 10, no. 4, pp. 8580–8603, 2015.
[9] S. S. Chee, M. Jawaid, M. T. H. Sultan, O. Y. Alothman, and L. C. Abdullah, “Thermomechanical and dynamic mechanical properties of bamboo/woven kenaf mat reinforced epoxy hybrid composites,” Composites Part B: Engineering, vol. 163, pp. 165– 174, 2019.
[10] A. F. M. Nor, M. T. H. Sultan, M. Jawaid, A. M. R. Azmi, and A. U. M. Shah, “Analysing impact properties of CNT filled bamboo/glass hybrid nanocomposites through drop-weight impact testing, UWPI and compression-after-impact behaviour,” Composites Part B: Engineering, vol. 168, pp. 166–174, 2019.
[11] S. D. Salman, Z. Leman, M. T. H. Sultan, M. R. Ishak, and F. Cardona, “Effect of kenaf fibers on trauma penetration depth and ballistic impact resistance for laminated composites,” Textile Research Journal, vol. 87, no. 17, pp. 2051–2065, 2017.
[12] P. Zakikhani, R. Zahari, M. T. H. Sultan, and D. L. Majid, “Thermal degradation of four bamboo species,” BioResources, vol. 11, no. 1, pp. 414– 425, 2016.
[13] Y. G. T. Girijappa, S. M. Rangappa, J. Parameswaranpillai, and S. Siengchin, “Natural fibers as sustainable and renewable resource for development of eco-friendly composites: A comprehensive review,” Frontiers in Materials, vol. 6, pp. 1–14, 2019.
[14] DE Editors, “Transforming Ankle Foot Orthosis with 3D Printing - Digital Engineering,” 2017. [Online]. Available: http://www.digitaleng.news/de/transforming-ankle-foot-orthosis-3d-printing/
[15] M. Walbran, K. Turner, and A. J. McDaid, “Customized 3D printed ankle-foot orthosis with adaptable carbon fibre composite spring joint,” Cogent Engineering, vol. 3, no. 1, pp. 1–11, 2016.
[16] Y. H. Cha, K. H. Lee, H. J. Ryu, I. W. Joo, A. Seo, D. H. Kim, and S. J. Kim, “Ankle-foot orthosis made by 3D printing technique and automated design software,” Applied Bionics and Biomechanics, vol. 2017, pp. 1–6, 2017.
[17] J. P. Deckers, M. Vermandel, J. Geldhof, E. Vasiliauskaite, M. Forward, and F. Plasschaert, “Development and clinical evaluation of lasersintered ankle foot orthoses,” Plastics Rubber and Composites, vol. 47, no. 1, pp. 42–46, 2018.
[18] L. Aydin and S. Kucuk, “A method for more accurate FEA results on a medical device developed by 3D technologies,” Polymers for Advanced Technologies, vol. 29, no. 8, pp. 2281–2286, 2018.
[19] E. Vasiliauskaite, A. Ielapi, M. D. Beule, W. V. Paepegem, J. P. Deckers, M. Vermandel, M. Forward, and F. Plasschaert, “A study on the efficacy of AFO stiffness prescriptions,” Disability and Rehabilitation: Assistive Technology, to be published, doi: 10.1080/17483107.2019.1629114.
[20] S. S. Bobby, S. Narayanan, and A. K. Nath, “A study on the strength of sintered part in SLS process by infiltration technique,” KMUTNB International Journal of Applied Science and Technology, vol. 5, no. 1, pp. 1–10, 2012.
[21] A. Chen, “Detail comparison of 3D printing methods: SLS vs FDM & SLA vs DLP,” 2019. [Online]. Available: https://www.cmac.com.au/blog/3d-printing-methods-side-by-side-comparisonsls- vs-fdm-sla-vs-dlp
[22] R. K. Chen, L. Chen, B. L. Tai, Y. Wang, A. J. Shih, and J. Wensman, “Additive manufacturing of personalized ankle-foot orthosis,” Transactions of the North American Manufacturing Research Institution of SME, vol. 42, pp. 381–389, 2014.
[23] Curbell Plastics, “ALL MATERIALS,” 2020. [Online]. Available: https://www.curbellplastics.com/Shop-Materials/All-Materials/#?Shape= CRBL.SkuSheet
[24] S. Dickins and T. Jarrott, “Head to foot ortho. catalogue august 2017,” 2020. [Online]. Available: https://www.htforthotics.com.au/images/documents/ HTFO Catalogue Rev 8 Web.pdf
[25] Pathway Pedorthic Footcare, “Pricing for Basic Services,” 2020. [Online]. Available: https:// www.pathwaypedorthicfootcare.com/pricing
[26] H. Watkin, “Father 3D Prints Orthoses for his Son, Now Helps Others,” 2018. [Online]. Available: https://all3dp.com/father-3d-prints-orthoses-sonnow-helps-others-company-nimake/
[27] Truity, “Orthotist or Prosthetist,” 2019. [Online]. Available: https://www.truity.com/career-profile/ orthotist-or-prosthetist
[28] ICRC, Manufacturing Guidelines Ankle-Foot Orthosis. International Committee of the Red Cross, Geneva, Switzerland, 2010.
[29] B. Goldschmidt, “3D Printer Material Cost – The Real Cost of 3D Printing Materials,” 2019. [Online]. Available: https://all3dp.com/2/3d-printer-materialcost-the-real-cost-of-3d-printing-materials/
[30] J. Flynt, “How Much Does 3D Printing Filament Cost?,” 2017. [Online]. Available: https:// 3dinsider.com/3d-printing-filament-cost/
[31] J. W. Gooch, “Tensile Strength at Yield,” 2011. [Online]. Available: https://omnexus. specialchem.com/polymer-properties/properties/strength-at-yield-tensile
[32] G. Hill, “Young’s Modulus,” 2019. [Online]. Available: https://omnexus.specialchem.com/ polymer-properties/properties/young-modulus
[33] R. M. Kumar, N. Rajini, T. S. M. Kumar, K. Mayandi, S. Siengchin, and S. O. Ismail, “Thermal and structural characterization of acrylonitrile butadiene styrene (ABS) copolymer blended with polytetrafluoroethylene (PTFE) particulate composite,” Materials Research Express, vol. 6, no. 8, pp. 1–6, 2019.
[34] L. Techawinyutham, S. Siengchin, R. Dangtungee, and J. Parameswaranpillai, “Influence of accelerated weathering on the thermo-mechanical, antibacterial, and rheological properties of polylactic acid incorporated with porous silica-containing varying amount of capsicum oleoresin,” Composites Part B: Engineering, vol. 175, pp. 1–8, 2019.
[35] B. Nim, P. Sreearunothai, P. Opaprakasit, and A. Petchsuk, “Preparation and properties of electrospun fibers of titanium dioxide-loaded polylactide/polyvinylpyrrolidone blends,” Applied Science and Engineering Progress, vol. 12, no. 1, pp. 52–58, 2019.
[36] S. Phongtamrug, P. Phakpharin, S. Soontaranon, and S. Rugmai, “Structural investigation of poly (lactic acid) cast film by using synchrotron X-ray scattering technique,” KMUTNB: International Journal of Applied Science and Technology, vol. 11, no. 2, pp. 151–155, 2018.