Adopting Additive Manufacturing Technologies for Orthotics Reflection Paper 1 paragraph reflecting on what you learned from the event and how it applies to

Adopting Additive Manufacturing Technologies for Orthotics Reflection Paper 1 paragraph reflecting on what you learned from the event and how it applies to your future goals. g technologies for orthotics and prosthetics
Enna Proctor!, Laura Leimkeuhler Mullin?, Peter Leimkuehler?,
rlikci!, Rika Carlsen!, Won Joo!
-., PA; Union Orthotics and Prosthetics Co., Pittsburgh, PA
Union
Isola
ORTHOTICS & PROSTHETICS CO.
Results
Sed
nologies have
ufacturing.
ltiple
Avg max load Avg max displacement
PETG
3977 N
65 mm
EVA
9788 N
63 mm
50% PLA
2064N
25 mm
85% PLA
2362 N
27 mm
100% PLA
24 mm
*Overflow error at 10000 N
Table 2: Average loads, displacement at failure.
• Voids in the 3DP sockets’ infill compromised
2386 N
re.
f3DP
ncluding:
dow (3D scan
utes total.
Figure 4: Finite element analysis of a PLA
socket under mechanical loading.
rials, and 3DP
socket integrity. Voids prohibit force distribution
around the whole socket.
• Another error present in the 3DP sockets is pitting
or over-extruding of the PLA during each layer
restart, also prohibiting force distribution
• Thickness in traditionally manufactured sockets is
4.5-5 mm (vs. 3 mm 3DP sockets). yielding higher
testing results. Repeating with 4.5-5 mm 3DP PLA
sockets may increase results.
olidworks) to
Conclusions
. All sockets (PLA, PETG, EVA) passed
2000 N before failure, meeting
acceptance criteria.
Optimal infill for PLA sockets between
85% and 100%
0328:2016(E)
th using an
sine set to
ed to failure.
before failure
person (safety
85% infill PLA 100% infill PLA
2386 N
24 mm
14 hr
500 g
Table 3: Comparison of 85%, 100% infill PLA results
Max load 2362 N
Displacement 27 mm
Print time
15 hr
Filament used 657 g
0% infill, 85%
cets, 3 EVA
Future work:
oExperimenting with various 3DP
filaments for greater strength and
durability:
.
e (PC)
Acrylonitrile butadiene styrene (ABS)
Further mechanical testing. FEA
simulations:
• Ultimate strength test
• 3-point bending test
Compression test
Polyurethane (TPU)
Acknowledgments
-PETG
IEVA
–50% PLA
85% PLA
-100% PLAN
grant from the
Development
This project was financed (w part by a
sylvania monwealth of
of Community &
M
Fure 3: Mechanical testing set-up
BARONET
pennsylvania PA
UNOMEDERO
30
20
Displacement (me)
placement results for mechanical testing.
dditive manufacturing technologies for orthotics and
Cheri McChesney!, Nicholas Dodds, Brianna Proctor!, Laura Leimkeuhler Mullin?, Peter Leimkuehler-
Arif Sirinterlikci!, Rika Carlsen!, Won Joo’
Robert Morris University, Moon Twp., PA; -Union Orthotics and Prosthetics Co., Pittsburgh, PA
Methods
Results
patient
cic as
ove,
soon
s and
3D scanning and 3D printing (3DP) technologies have
the potential to replace traditional manufacturing,
but requires developing solutions for multiple
technical challenges, including:
Design process time.
• Strength of 3DP materials and structure.
• Printing time and cost.
BAL
Union O&P, is
ecific medical
Avg max load Avg max displacement
PETG
3977 N
65 mm
EVA
9788 N
63 mm
50% PLA
2064 N
25 mm
85% PLA
2362 N
27 mm
100% PLA
2386 N
24 mm
*Overflow error at 10000 N
Table 2: Average loads, displacement at failure.
. Voids in the 3DP sockets’ infill compromised
socket integrity. Voids prohibit force distribution
around the whole socket.
• Another error present in the 3DP sockets is pitting
or over-extruding of the PLA during each layer
restart, also prohibiting force distribution.
• Thickness in traditionally manufactured sockets is
4.5-5 mm (vs. 3 mm 3DP sockets), yielding higher
testing results. Repeating with 4.5-5 mm 3DP PLA
sockets may increase results.
ces. The
nufacturing
ensive process
Figure
d materials.
so
Design, verification, and validation of 3DP
prosthetic sockets is being performed, including:
• Optimization of device design workflow (3D scan
to printed socket) to less than 20 minutes total.
• Optimization of socket shape, materials, and 3DP
parameters.
• Finite Element Analysis (Abaqus, Solidworks) to
match all physical tests.
• Mechanical testing based on ISO 10328:2016(E)
and ISO 22523:2006.
Currently testing the static strength using an
Instron 5585 tension testing machine set to
compression at 10 mm/min, loaded to failure.
Acceptance criteria:
2000 N load before failure
based on full weight of a 150 lb person (safety
Testing 3 each of 3DP sockets (50% infill, 85%
infill, 100% infill), 3 PETG sockets, 3 EVA
sockets (Total: 15 sockets)
ost, improve
e outsourcing
ing closely with
3DP techniques
. All sock
2000 N
acceptan
• Optimal
85% and
2362 N
chniques and
nion O&P’s 14
patients they
mpanies across
85% infill PLA 100% infill PLA
Max load
2386
Displacement 27 mm 24 mm
Print time 15 hr
14 hr
Filament used 657 g
500 g
Table 3: Comparison of 85%, 100% infill PLA results.
factor 3).
Disadvantages
Brittle
Crushed at failure
ay
Stift
Future wo
oExperim
filament:
durability
•Thermo
-Polycar
• Acrylon
Furthermo
simulation
– Ultimate
3-point be
P
point
or
ity
Labor-intensive
process with much
e effort,
materials
-PETG
-EVA
-50% PLA
85% PLA
-100% PLA
e
time
-Compress
Ackno
This project was
grant from the ce
Persylvania Dep
Economic Develop
le I (above): Socket
erials list.
are 1 (left): 3DP PLA
kets.
30
Figure 3: Mechanical testing set-up.
Displacement (M)
10
Figure 2: Load-displacement results for mechanical testing.
RMU
Adopting additive manufacturing technologies for orthotics and prosthetics
Union
ROBERT MORRIS
Cheri McChesneyl. Nicholas Dodds!, Brianna Proctor’, Laura Leimkeuhler Mullin, Peter Leimkuehler,
Arif Sirinterlikcil, Rika Carlsen!, Won Jool
Robert Morris University, Moon Twp., PA: -Union Orthotics and Prosthetics Co., Pittsburgh, PA
OWTHORS & PROSTHEco
Results
Introduction
Project Motivation:
Development of custom devices to match patient
anatomy is becoming increasingly realistic as
additive manufacturing technologies improve
specifically 3D-printing (3DP). 3DP will soon
Methods
3D scanning and 3D printing (3DP) technologies have
the potential to replace traditional manufacturing,
but requires developing solutions for multiple
technical challenges, including
• Design process time.
• Strength of 3DP materials and structure.
Printing time and cost
50% PLA
become the gold standard for the orthotics and
prosthetics (O&P) field.
Robert Morris University (RMU), with Union ORP, is
exploring the use of 3DP for patient-specific medical
devices in the O&P industry. Union ORP
manufactures various custom O&P devices. The
company currently uses a traditional manufacturing
method for custom devices, a labor intensive process
Avmax load Ang tax placement
PETG 3977 NI
65mm
EVA
9788 N
2064N
284 PLA
2362 N
27 mm
100% PLA 2.386 N
24 mm
“Overflow error 10000 N
Table 2: Average loads, displacement failure.
• Volds in the 3DP sockets will compromised
socket integrity. Volds prohibit force distribution
around the whole socket
• Another error present in the JDP sockets is plitting
or over-extrading of the PL.A during each layer
restart, also prohibiting force distrito
• Thickness in traditionally manufactured sockets is
4.5-5 mm (vs. 3 mm 3DP ke Lyding higher
testing results. Repeating with 4.5-3 TOPLA
sockets may increase results
Figure 4: Finite element analysis of a PLA
socket ander mechanical loading
blogy
Design, verification, and validation of 3DP
prosthetic sockets is being performed, including
• Optimization of device design workflow (3D wani
to printed socket) to less than 20 minutes total
• Optimization of socket shape, materials, and 3DP
parameters. ,
• Finite Element Analysis (Abaqus, Solidworks) to
match all physical tests.
• Mechanical testing based on ISO 10328.2016)
and ISO 22523:2006
Currently testing the static strength using an
Instron 5585 tension testing machine set to
compression at 10 mm/min, loaded to failure
Acceptance criteria: 2000 N load before failure
based on full weight of a 150 lb person (safety
factor 3).
Testing each of SDP sockets (50% infill, 8546
inti, 100% infill), 3 PETG sockets. 3 VA
sockets (Total: 15 sockets)
that requires significant time, effort, and materials
Objective, Impact on PA:
To reduce manufacturing time and cost, improve
patient satisfaction, and minimize the outsourcing
of certain components, RMU is working closely with
Union De P to develop and integrate 3D techniques
for their custom O&P needs. These techniques and
their benefits will not only improve Union Ps 14
Pittsburgh area offices and the many patients they
the
he
1859 infil PLA 100% infill PLA
Max load
2362 N 12356N
Displacement 27 men mm
Print time 15
14 h
Filament used 1657
1500
Table 3-Comprises of 85.100 in PLA results.
Conclusions
All sockets PLA, PETG, EVA) passed
2000 N hefore Padure, meeting
acceptance criteria
Optimal info for PLA sockets between
8596 and 100%
Future work
Experimenting with various DP
filaments for greater strength and
durability:
Thermoplastic polyurethane (TPU)
-Polycarbonate (PC)
Acrylonitrile talene styrene (ABS)
burret mechanical testing. FEA
imalalam
Nimale stretches
Competentes
Tpeat
le
Serve, but can also be used in Que Pompanies across
Carted at fire
the state and around the world
much
3DP sockets
bendin
-PETG
-EVA
– -SOPLA
-25% PLA
-1004 PLAU
Laberi
process with me
time, in
man
Acknowledgments
PETO
This project was import by a
Material Advantages
PLA
Most OPSO
Cheap
20 min of labor
Prints
High deformability
High come
TEVA
មហh
Proverb
Table (above) Seck
materials st.
Figure I left: OPPLA
och
gel from the Commonwealth
Pennywila Dome of Cavanity
Vicon Develogen
Traditional
10
sockets
10
Dame
Fine
Pove: Louisplacement
penos
Bernsylvand
PA
17
Adopting additive manufacturing te
RMU
ROBERT MORRIS
Cheri McChesney!, Nicholas Dodds!, Brianna Pro
Arif Sirinterlikci!, F
Robert Morris University, Moon Twp., PA; 20
Introduction
Methods
Project Motivation:
Development of custom devices to match patient
anatomy is becoming increasingly realistic as
additive manufacturing technologies improve,
specifically 3D-printing (3DP). 3DP will soon
become the gold standard for the orthotics and
prosthetics (O&P) field.
Robert Morris University (RMU), with Union O&P, is
exploring the use of 3DP for patient-specific medical
3D scanning and 3D printing (3DP) technologies have
the potential to replace traditional manufacturing,
but requires developing solutions for multiple
technical challenges, including:
• Design process time.
• Strength of 3DP materials and structure,
• Printing time and cost.
devices in the O&P industry. Union O&P
manufactures various custom O&P devices. The
company currently uses a traditional manufacturing
method for custom devices, a labor-intensive process
that requires significant time, effort, and materials
Design, verification, and validation of 3DP
prosthetic sockets is being performed, including:
• Optimization of device design workflow (3D scan
to printed socket) to less than 20 minutes total.
• Optimization of socket shape, materials, and 3DP
parameters,
• Finite Element Analysis (Abaqus, Solidworks) to
match all physical tests.
• Mechanical testing based on ISO 10328:2016(E)
and ISO 22523:2006.
Currently testing the static strength using an
Instron 5585 tension testing machine set to
compression at 10 mm/min, loaded to failure.
Acceptance criteria: 2000 N load before failure
Objective, Impact on PA:
To reduce manufacturing time and cost, improve
based on full weight of a 150 lb person (safety
patient satisfaction, and minimize the outsourcing
Union O&P to develop and integrate 3DP techniques
their benefits will not only improve Union O&P’s 14
Serve, but can also be used in O&P companies across
of certain components, RMU is working closely with
for their custom O&P needs. These techniques and
Pittsburgh area offices and the many patients they
factor 3).
o Testing 3 each of 3DP sockets (50% infill, 85%
Disadvantages
infill, 100% infill), 3 PETG sockets, 3 EVA
Max
Displ:
Print
Filame
Table
sockets (Total: 15 sockets)
Stiff
Brittle
the state and around the world.
Crushed at failure
point
4
3DP sockets
Labor-intensive
process with much
time, effort,
High der
Material Advantages
PLA
Most common 3DP
material
Cheap
20 minutes of labor
Prints
High compressive
strength
TEVA
materials
Table I (above): Socket
materials list.
Figure 1 (left): 3DP PLA
socker
PETG
Traditional
Proven reliable
Force (kN)
sockets
10
20
Figure 2: Load-displacement results for mechanical testin
Displacement (m.)
40

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