Assessment of the non-linear behaviour of plastic ankle foot orthoses by the finite element method

Computational modelling of ankle-foot orthosis to evaluate spatially asymmetric structural stiffness: Importance of geometric nonlinearity

An ankle-foot orthosis (AFO) constructed as a single piece of isotropic elastic material is a commonly used assistive device that provides stability to the ankle joint of patients with spastic diplegic cerebral palsy. The AFO has asymmetric stiffness that restricts plantarflexion during the swing phase while it is flexible to allow dorsiflexion during the stance phase with a large deflection, including buckling originating from geometric nonlinearity. However, its mechanical implications have not been sufficiently investigated. This study aims to develop a computational model of an AFO considering geometric nonlinearity and examine AFO stiffness asymmetry during plantarflexion and dorsiflexion using physical experiments. Three-dimensional AFO mechanics with geometric nonlinearities were expressed using corotational triangle-element formulations that obeyed Kirchhoff-Love plate theory. Computational load tests for plantarflexion and dorsiflexion, using idealised AFOs with two different ankle-region designs (covering or not covering the apexes of the malleoli), showed that plantarflexion moment-ankle angle relationships were linear and dorsiflexion moment-ankle angle relationships were nonlinear; increases in dorsiflexion led to negative apparent stiffness of the AFO. Both ankle-region designs resisted both plantarflexion and dorsiflexion, and out-of-plane elastic energy was locally concentrated on the lateral side, resulting in large deflections during dorsiflexion. These findings give insight into appropriate AFO design from a mechanical viewpoint by characterising three-dimensional structural asymmetry and geometric nonlinearity.

A digital workflow for personalized design of the interface parts integrated in a powered ankle foot orthosis (PAFO)

The use of actuated exoskeletons in gait rehabilitation increased significantly in recent years. Although most of these exoskeletons are produced with a generic cuff, at the foot and ankle there are a lot of bony prominences and a limited amount of soft tissue, making it less comfortable . Furthermore, a proper alignment of the actuation systems is essential for the correct functioning of the exoskeleton. Therefore, we propose a digital workflow for the design of bespoke cuffs as interface parts of a powered ankle foot orthoses (PAFO). Moreover, this digital workflow permits the creation of axis and points of reference for the anatomical features which allows not only for the creation of custom-made cuffs but also for the integration and alignment of the PAFO mechanical components and actuation unit.

A validated computational framework to evaluate the stiffness of 3D printed ankle foot orthoses

The purpose of this study was to create and validate a standardized framework for the evaluation of the ankle stiffness of two designs of 3D printed ankle foot orthoses (AFOs). The creation of four finite element (FE) models allowed patient-specific quantification of the stiffness and stress distribution over their specific range of motion during the second rocker of the gait. Validation was performed by comparing the model outputs with the results obtained from a dedicated experimental setup, which showed an overall good agreement with a maximum relative error of 10.38% in plantarflexion and 10.66% in dorsiflexion. The combination of advanced computer modelling algorithms and 3D printing techniques clearly shows potential to further improve the manufacturing process of AFOs.

Analysis and comparison of wrist splint designs using the finite element method: Multi-material three-dimensional printing compared to typical existing practice with thermoplastics

Rheumatoid arthritis is a chronic disease affecting the joints. Treatment can include immobilisation of the affected joint with a custom-fitting splint, which is typically fabricated by hand from low temperature thermoplastic, but the approach poses several limitations. This study focused on the evaluation, by finite element analysis, of additive manufacturing techniques for wrist splints in order to improve upon the typical splinting approach. An additive manufactured/3D printed splint, specifically designed to be built using Objet Connex multi-material technology and a virtual model of a typical splint, digitised from a real patient-specific splint using three-dimensional scanning, were modelled in computer-aided design software. Forty finite element analysis simulations were performed in flexion-extension and radial-ulnar wrist movements to compare the displacements and the stresses. Simulations have shown that for low severity loads, the additive manufacturing splint has 25%, 76% and 27% less displacement in the main loading direction than the typical splint in flexion, extension and radial, respectively, while ulnar values were 75% lower in the traditional splint. For higher severity loads, the flexion and extension movements resulted in deflections that were 24% and 60%, respectively, lower in the additive manufacturing splint. However, for higher severity loading, the radial defection values were very similar in both splints and ulnar movement deflection was higher in the additive manufacturing splint. A physical prototype of the additive manufacturing splint was also manufactured and was tested under normal conditions to validate the finite element analysis data. Results from static tests showed maximum displacements of 3.46, 0.97, 3.53 and 2.51 mm flexion, extension, radial and ulnar directions, respectively. According to these results, the present research argues that from a technical point of view, the additive manufacturing splint design stands at the same or even better level of performance in displacements and stress values in comparison to the typical low temperature thermoplastic approach and is therefore a feasible approach to splint design and manufacture.

Posterolateral ankle ligament injuries affect ankle stability: a finite element study

BACKGROUND

We have already discovered 23 patients during the work of the outpatient department and operations whose unstable signs on the posterolateral ankle. The anterior drawer test demonstrated normal during the physical examinations while the spaces of the posterior tibiotalar joints increased in stress X-ray plain films. ATFL intact and posterolateral ligaments lax were found during operations too. It is important to make existence claims and illuminate the mechanism of posterolateral ankle instability.

METHODS

A finite element model of the ankle was established for simulating to cut off posterolateral ligaments in turn. Ankle movements with tibia rotation under load on five forefoot positions were simulated as well.

RESULTS

The difference values with tibia external rotation were negative, and the positive results occurred with tibia internal rotation. The tibia-talus difference values in some forefoot positions were 2 ~ 3 mm after PTFL together with CFL or/and PITFL were cut off. The tibula-talus difference values were 2.21 ~ 2.76 mm after both PTFL and CFL were cut off. The tibia-fibula difference values were small. The difference values increased by 2 ~ 5 mm after cutting off the PITFL.

CONCLUSIONS

Posterolateral ankle ligaments, especially CFL and PITFL, play a significant role in maintaining ankle stability. The serious injuries of both CFL and PITFL would affect posterolateral ankle stabilities. PITFL was important to subtalar joint stability.

Experimental and computational analysis of composite ankle-foot orthosis

Carbon fiber (CF) ankle-foot orthoses (AFOs) can improve gait by increasing ankle plantar-flexor power and improving plantar-flexor ankle joint moment and energy efficiency compared with posterior leaf spring AFOs made of thermoplastic. However, fabricating a CF AFO to optimize the performance of the individual user may require multiple AFOs and expensive fabrication costs. Finite element analysis (FEA) models were developed to predict the mechanical behavior of AFOs in this study. Three AFOs, two made of CF composite material and one made of thermoplastic material, were fabricated and then mechanically tested to produce force-displacement data. The FEA models were validated by comparing model predictions with mechanical testing data performed under the same loading and boundary conditions. The actual mechanical testing demonstrated that CF performs better than thermoplastic. The simulation results showed that FEA models produced accurate predictions for both types of orthoses. The relative error of the energy return ratio predicted by the CF AFO FEA model developed in this study is less than 3%. We conclude that highly accurate FEA models will allow orthotists to improve CF AFO fabrication without wasting resources (time and money) on trial and error fabrications that are expensive and do not consistently improve AFO and user performance.

Determination of loads carried by polypropylene ankle-foot orthoses: a preliminary study

Ankle-foot orthoses (AFOs) are prescribed for the management of gait-related problems. Prescription of AFOs is based on empirical techniques due to the low level of evidence-based research on their efficacy, but primarily poor understanding of their mechanical characteristics. This study aimed to establish a method that would allow the quantification of the contribution of AFOs in the control of the ankle joint during gait. A possible way of achieving this aim would be to measure strain on the AFO during walking by the use of strain gauges. Following successful experimentation with the application of strain gauges to polypropylene tensile specimens, an AFO was instrumented by attaching strain gauges to it so as to allow the moment generated on the AFO in the sagittal plane about the ankle to be measured. Walking trials using this AFO on an able-bodied subject indicated good step-to-step repeatability. The use of an instrumented AFO in conjunction with kinematic and kinetic data acquisition would allow the contribution of the AFO and the residual anatomical loads to be determined. The advantage of such procedure over previously reported ones resides on the use of the actual orthosis being worn by patients thereby conducting tests under real-life situations. It is believed that such analysis of the load actions of an orthosis, which may in future be carried out in three dimensions, would allow a better understanding of the interaction between the leg and the orthosis. This should ultimately enhance AFO prescription criteria and help in optimising patient/device matching.

Assessment of a virtual functional prototyping process for the rapid manufacture of passive-dynamic ankle-foot orthoses

Passive-dynamic ankle-foot orthosis (PD-AFO) bending stiffness is a key functional characteristic for achieving enhanced gait function. However, current orthosis customization methods inhibit objective premanufacture tuning of the PD-AFO bending stiffness, making optimization of orthosis function challenging. We have developed a novel virtual functional prototyping (VFP) process, which harnesses the strengths of computer aided design (CAD) model parameterization and finite element analysis, to quantitatively tune and predict the functional characteristics of a PD-AFO, which is rapidly manufactured via fused deposition modeling (FDM). The purpose of this study was to assess the VFP process for PD-AFO bending stiffness. A PD-AFO CAD model was customized for a healthy subject and tuned to four bending stiffness values via VFP. Two sets of each tuned model were fabricated via FDM using medical-grade polycarbonate (PC-ISO). Dimensional accuracy of the fabricated orthoses was excellent (average 0.51 ± 0.39 mm). Manufacturing precision ranged from 0.0 to 0.74 Nm/deg (average 0.30 ± 0.36 Nm/deg). Bending stiffness prediction accuracy was within 1 Nm/deg using the manufacturer provided PC-ISO elastic modulus (average 0.48 ± 0.35 Nm/deg). Using an experimentally derived PC-ISO elastic modulus improved the optimized bending stiffness prediction accuracy (average 0.29 ± 0.57 Nm/deg). Robustness of the derived modulus was tested by carrying out the VFP process for a disparate subject, tuning the PD-AFO model to five bending stiffness values. For this disparate subject, bending stiffness prediction accuracy was strong (average 0.20 ± 0.14 Nm/deg). Overall, the VFP process had excellent dimensional accuracy, good manufacturing precision, and strong prediction accuracy with the derived modulus. Implementing VFP as part of our PD-AFO customization and manufacturing framework, which also includes fit customization, provides a novel and powerful method to predictably tune and precisely manufacture orthoses with objectively customized fit and functional characteristics.

Effects of joint alignment and type on mechanical properties of thermoplastic articulated ankle-foot orthosis

BACKGROUND

Articulated or hinged ankle-foot orthosis (AFO) allow more range of motion. However, quantitative investigation on articulated AFO is still sparse.

OBJECTIVE

The objective of the study was to quantitatively investigate effects of alignment and joint types on mechanical properties of the thermoplastic articulated AFO.

STUDY DESIGN

Tamarack dorsiflexion assist flexure joints with three durometers (75, 85 and 95) and free motion joint were tested. The AFO joint was aligned with the center of the motor shaft (surrogate ankle joint), 10 mm superior, inferior, anterior and posterior with respect to the motor shaft center.

METHODS

The AFO was passively moved from 20° plantar flexion to 15° dorsiflexion at a speed of 10°/s using a motorized device. Mechanical properties including index of hysteresis, passive resistance torque and quasi-static stiffness (at neutral, 5°, 10° and 15° in plantar flexion) were quantified.

RESULTS

Significant effects of joint types and joint alignment on the mechanical properties of an articulated thermoplastic AFO were revealed. Specifically, center alignment showed minimum resistance and stiffness while anterior and posterior alignment showed significantly higher resistance and stiffness. The dorsiflexion assist torques at neutral position ranged from 0.69 ± 0.09 to 1.88 ± 0.10 Nm.

CONCLUSIONS

Anterior and posterior alignment should be avoided as much as possible.

CLINICAL RELEVANCE

The current study suggested that anterior and posterior alignment be avoided as much as possible in clinical practice due to potential skin irritation and increase in stress around the ankle joint.

Development of a method for fabricating polypropylene non-articulated dorsiflexion assist ankle foot orthoses with predetermined stiffness

BACKGROUND

A non-articulated plantarflexion resist ankle foot orthosis (AFO), commonly known as a posterior leaf spring AFO, is indicated for patients with motor impairment to the dorsiflexors. The AFO is often custom molded to a patient's lower limb anatomy and fabricated from polypropylene. There are no established guidelines for fabricating this type of AFO with predetermined stiffness of the ankle region for normal walking speeds. Therefore an AFO may not meet the biomechanical needs of the patient.

OBJECTIVES

Quantify the biomechanical ankle stiffness requirement for an individual with complete dorsiflexor impairment and develop a method for fabricating an AFO with ankle stiffness to meet that requirement.

STUDY DESIGN

Experimental, bench research.

METHODS

The literature on sagittal biomechanics of non-pathological adults was reviewed to derive the stiffness of the ankle during loading response. Computer models of 144 AFOs were created with geometric variations to account for differences in human anthropometrics. Computer-based finite element analysis was employed to determine the stiffness and safety factor of the models.

RESULTS

Stiffness of the AFOs ranged from 0.04 to 1.8 Nm/deg. This ample range is expected to account for the stiffness required for most adults with complete dorsiflexor impairment. At 5° deflection the factor of safety (ratio of strength to stress) ranged from 2.8 to 9.1. A computer program was generated that computes AFO stiffness from user-input variables of AFO geometry. The stiffness is compared to a theoretically appropriate stiffness based on the patient mass. The geometric variables can be modified until there is a close match, resulting in AFO design specification that is appropriate for the patient.

CONCLUSION

Through validation on human subjects, this method may benefit patient outcomes in clinical practice by avoiding the current uncertainty surrounding AFO performance and reducing the labor and time involved in rectifying a custom AFO post-fabrication.

CLINICAL RELEVANCE

This method provides an avenue for improving patient outcomes by avoiding the current uncertainty surrounding non-articulated plantarflexion resist ankle foot orthosis performance. The ability to quantify the biomechanical ankle stiffness requirement for an individual with complete dorsiflexor impairment provides insight into how other AFO types should be designed as well.

Parametric design of pressure-relieving foot orthosis using statistics-based finite element method

Custom-molded foot orthoses are frequently prescribed in routine clinical practice to prevent or treat plantar ulcers in diabetes by reducing the peak plantar pressure. However, the design and fabrication of foot orthosis vary among clinical practitioners and manufacturers. Moreover, little information about the parametric effect of different combinations of design factors is available. As an alternative to the experimental approach, therefore, computational models of the foot and footwear can provide efficient evaluations of different combinations of structural and material design factors on plantar pressure distribution. In this study, a combined finite element and Taguchi method was used to identify the sensitivity of five design factors (arch type, insole and midsole thickness, insole and midsole stiffness) of foot orthosis on peak plantar pressure relief. From the FE predictions, the custom-molded shape was found to be the most important design factor in reducing peak plantar pressure. Besides the use of an arch-conforming foot orthosis, the insole stiffness was found to be the second most important factor for peak pressure reduction. Other design factors, such as insole thickness, midsole stiffness and midsole thickness, contributed to less important roles in peak pressure reduction in the given order. The statistics-based FE method was found to be an effective approach in evaluating and optimizing the design of foot orthosis.

A 3-dimensional finite element model of the human foot and ankle for insole design

OBJECTIVE

To investigate the effect of material stiffness of flat and custom-molded insoles on plantar pressures and stress distribution in the bony and ligamentous structures during balanced standing.

DESIGN

A 3-dimensional (3-D) finite element model of the human ankle-foot complex and a custom-molded insole were developed from 3-D reconstruction of magnetic resonance images and surface digitization. The distal tibia and fibula, together with 26 foot bones and 72 major ligaments and the plantar fascia, were embedded in a volume of soft tissues.

SETTING

Computational laboratory in a rehabilitation engineering center.

PARTICIPANT

A healthy man in his mid twenties (weight, 70 kg).

INTERVENTIONS

Not applicable.

MAIN OUTCOME MEASURES

Foot-support interfacial pressure, von Mises stress in bony structures, and strain of the plantar fascia were predicted using the finite element model.

RESULTS

A custom-molded, soft (Young modulus, E=0.3 MPa) insole reduced the peak plantar pressure by 40.7% and 31.6% at the metatarsal and heel region, respectively, compared with those under a flat, rigid (E=1000 MPa) insole. Meanwhile, a 59.7% increase in the contact area of the plantar foot was predicted with a corresponding peak plantar pressure increase of 22.2% in the midfoot.

CONCLUSIONS

The finite element analysis implies that the custom-molded shape is more important in reducing peak plantar pressure than the stiffness of the insole material.

A three centre study of the variability of ankle foot orthoses due to fabrication and grade of polypropylene

This study investigates if fabrication techniques employed at different orthotic centres affect the characteristics of the manufactured plastic orthoses. Plaster models were formed from the same master mould. The thickness and bending stiffness of the supplied polypropylene sheets were measured prior to fabrication. An orthotic technician at each of the 3 orthotic centres manufactured 4 homopolymer and 4 copolymer polypropylene ankle-foot orthoses (AFOs), following each centre's fabrication practice. Another technician at one of the orthotic centres manufactured an additional 4 homopolymer and 4 copolymer AFOs. The thickness, the dorsiflexion stiffness and plantarflexion stiffness of the 32 fabricated AFOs were monitored and compared. Analysis of the results suggests: Copolymer polypropylene sheets are supplied marginally thicker than homopolymer polypropylene sheets. The difference between the thickness of the 16 copolymer and 16 homopolymer AFOs was not significant. The thickness of the AFOs manufactured in copolymer was less consistent than homopolymer. Dorsiflexion stiffness of the copolymer AFOs was less consistent than homopolymer AFOs. Although the bending stiffness of the copolymer and homopolymer sheets differed significantly, there was no significant difference between the dorsiflexion stiffness of the copolymer and homopolymer AFOs. Plantarflexion stiffness was consistent for both the copolymer and the homopolymer AFOs and there was no significant difference between the plantarflexion stiffness of the copolymer and homopolymer AFOs. The thickness and flexural stiffness of the AFOs manufactured by 2 technicians at the same centre did not differ. These results are useful benchmarks for the flexural stiffness of AFOs.

A Novel Device to Evaluate the Stiffness of Ankle-Foot Orthosis Devices

The evaluation of mechanical behavior of plastic Ankle-Foot Orthosis (AFO) is important since AFO can provide an efficient support to patients with disabilities in locomotion. This paper reports on a novel testing apparatus that allows: (a) the evaluation of AFO stiffness in sagittal and frontal planes; (b) the conduction of semi-automatic trials; and, finally, (c) a global accuracy associated to the AFO stiffness values always less than 4%. The stiffness values are determined by the measurements of the imposed relative displacements between the foot and the shank of the orthosis and the induced reaction forces. The data collected together in an exact 2-D approach, together with those provided by gait analysis systems, allows to better understand gait alteration induced by ankle orthosis, and to improve clinical management of patients.