Use of additive manufacturing processes in the manufacture of custom orthoses
AssigneeCropper Medical, Inc.
InventorJoseph T. Zachariasen
Life of this patent
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Abstract
A method for manufacturing a custom orthosis, such as an ankle brace, includes use of scanning processes. A digital model of a surface may be applied to a digital orthosis model to define a custom digital orthosis model. The digital model and, thus, the custom digital orthosis model may include one or more standard features. The custom digital orthosis model may be used with an automated manufacturing process to make some or all of the custom orthosis. In some embodiments, additive manufacturing processes may be used to form a portion or all of the custom orthosis.
Claims43
A method for fabricating a custom orthosis, comprising:
- generating a digital negative model of a body part for which a custom orthosis is to be made, the digital negative model including custom surface data corresponding to at least one surface of the body part;
- applying the digital negative model to a digital orthosis model to incorporate the custom surface data into a customizable area of the digital orthosis model to create a custom digital orthosis model;
- and
- using the custom digital orthosis model to fabricate the custom orthosis for use on the body part.
A custom orthosis, comprising at least one surface configured to form fit to a body part of a subject, the at least one surface being defined by a plurality of separately defined, adjacent, integrated sections configured to impart the custom orthosis with flexibility and strength.
A system for fabricating a custom orthosis, comprising:
- a physical model generation component at which a physical model of a body part of a patient is made;
- a custom orthosis manufacturing component remote from the physical model generation component, the custom orthosis manufacturing component including:
- a scanner for obtaining surface contour data corresponding to a contour of at least one surface of a body part;
- a processing element programmed to apply the surface contour data to a digital orthosis model to define a custom digital orthosis model;
- and
- an additive manufacturing system configured to use the custom digital orthosis model to fabricate a custom orthosis.
Dependencies are inferred from the claim text.