Development of an AFO with dual-material using an FDM printer

Abstract

This paper presents a design and development of an Ankle Foot Orthosis (AFO) printed with a multi-extrusion Fused Deposition Modelling (FDM) printer. AFO is crucial in the healing of patients with ankle joint displacement. It helps to heal the foot easily. The model is designed to print with dual materials such as flex and polylactic acid (PLA). The critical problem in building a prototype is to obtain excellent bonding properties between the layers of different materials. The Flex material is softer than the PLA and both have different melting temperatures. Thus, successfully printing with an excellent adhesive is the key concern in multi-material applications. The paper also presents the simulation results of an AFO to justify the mechanical properties and required materials for sustainable development.