Abstract/References

Remote Orthotic Fabrication Method Using Small Three-Dimensional Printers and Computed Tomography Data: A Technical Report

Takeru Yokota, Takuya Nikaido, Masanori Abe, Yoshihiro Kikuchi, Shinichi Konno, Miho Sekiguchi, Takuya Kameda, Yojiro Takahashi, Katsuhiro Yoshida, Yasufumi Sekiguchi, Yoshihiro Matsumoto

Author information
  • Takeru Yokota
    Department of Orthopaedic Surgery, Fukushima Medical University
  • Takuya Nikaido
    Department of Orthopaedic Surgery, Fukushima Medical University
  • Masanori Abe
    Touhoku Prosthetic and Orthotic Co., LTD
  • Yoshihiro Kikuchi
    Touhoku Prosthetic and Orthotic Co., LTD
  • Shinichi Konno
    Department of Orthopaedic Surgery, Fukushima Medical University
  • Miho Sekiguchi
    Department of Orthopaedic Surgery, Fukushima Medical University
  • Takuya Kameda
    Department of Orthopaedic Surgery, Fukushima Medical University
  • Yojiro Takahashi
    Department of Orthopaedic Surgery, Fujita General Hospital
  • Katsuhiro Yoshida
    Department of Orthopaedic Surgery, Fujita General Hospital
  • Yasufumi Sekiguchi
    Department of Orthopaedic Surgery, Fujita General Hospital
  • Yoshihiro Matsumoto
    Department of Orthopaedic Surgery, Fukushima Medical University

Abstract

Introduction:Computer-aided design and manufacturing (CAD/CAM) methods have gained prominence in early orthotic provision. This study introduces an innovative approach using compact three-dimensional (3D) printers and computed tomography data to generate segmented body models for traditional Damen corset orthoses. The goals included evaluating the comfort and fit of orthoses and assessing the effectiveness of our approach for prosthetic companies with limited financial resources.

Materials and Methods:Lumbar and thoracolumbar orthoses were crafted via CAD/CAM. Four healthy patients wore the orthoses, with whom immediate and 1-week comfort and fit assessments were conducted. A prosthetist assessed fit, and the Japanese edition of OPUS-CSD, the Orthotics Prosthetics Users’ Survey-Client Satisfaction with Device, was used for subjective assessment of comfort and fit.

Results:The fit evaluations were satisfactory for all patients with positive predefined criteria. Questionnaire responses confirmed high satisfaction and comfort, confirming a successful orthosis fit.

Conclusion:We established an orthotic fabrication method using CAD/CAM methods with 3D printers. Additionally, we confirmed the comfort and fit of the corsets so produced. The initial cost of 3D printers is lower than that of traditional carving machines, enabling even small-scale orthotic fabrication facilities to utilize CAD/CAM methods. Further research and refinements of this manufacturing approach are expected to expand its applicability.

The content of research paper

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Figures

Flowchart illustrating the process of creating corsets using 3D scanning and modeling techniques.
3D model of a distorted container displayed in various angles, showcasing its shape and texture.
Images of a medical back brace displayed from various angles, showcasing its design and fastening mechanisms.
Table displaying three-dimensional printing parameters, including nozzle diameter, printing material, layer height, and printing speed.
Table displaying results of a prosthetic evaluation questionnaire assessing fit and safety for short and long damon corsets.
Table displaying a patient self-administered questionnaire on orthosis comfort and fit.
Table displaying a patient self-administered questionnaire regarding comfort and fit of a long Damen corset.

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