Biomechanical Simulation Accelerates Prosthetic and Orthotic Design Cycles

Why It Matters

This approach allows for rapid iteration and optimization of designs before physical prototyping, leading to more functional and comfortable assistive devices. It bridges the gap between theoretical design and real-world application by providing a data-driven method for validating complex biomechanical requirements.

Key Finding

Additive manufacturing, when integrated with biomechanical simulation and a systematic design framework, can overcome the limitations of traditional methods to create better-fitting and more functional prosthetics and orthotics.

Key Findings

• Traditional fabrication of prosthetics and orthotics is material-wasting, time-consuming, and labor-intensive.
• Additive manufacturing offers potential solutions to these challenges.
• A key challenge is the lack of an integrated technology framework for AM in this field.
• Designing for both comfort and function is crucial.
• Biomechanical evaluation using computational methods (like FEA) is essential for product optimization.

Research Evidence

Aim: How can biomechanical simulation be integrated into an additive manufacturing workflow to optimize the design and performance of prosthetics and orthotics?

Method: Systematic review and proposed framework development.

Procedure: The study reviewed current applications of additive manufacturing in prosthetic and orthotic fabrication, identified challenges, and proposed a systematic framework. This framework integrates computational design methods and biomechanical evaluations, including finite-element analysis, into the AM process from body part scanning to final product design.

Context: Prosthetic and orthotic clinics, assistive device design.

Design Principle

Integrate computational modelling and simulation early and iteratively within the design and manufacturing process for complex, performance-critical products.

How to Apply

When designing custom medical devices or performance-critical components, utilize CAD software with integrated simulation capabilities to test and refine designs virtually before committing to physical production.

Limitations

The effectiveness of the proposed framework relies on the accuracy of scanning data, the fidelity of simulation models, and the availability of robust AM processes for the specific materials and geometries required.

Student Guide (IB Design Technology)

Simple Explanation: Using computer simulations to test how well a prosthetic or brace will work before making it can save time and lead to a better final product.

Why This Matters: This research shows how using computer models to test designs can make the process of creating custom assistive devices much more efficient and effective, leading to better outcomes for users.

Critical Thinking: To what extent can biomechanical simulation fully replace physical prototyping in the development of assistive devices, and what are the risks associated with over-reliance on virtual testing?

IA-Ready Paragraph: The integration of additive manufacturing with biomechanical simulation, as highlighted by Wang et al. (2020), offers a powerful approach to accelerate the design and optimization of custom assistive devices. By employing computational modelling and finite-element analysis within a structured workflow, designers can iteratively refine prosthetic and orthotic designs to meet complex functional and comfort requirements more efficiently than traditional methods.

Project Tips

• When designing a product that needs to withstand forces or fit precisely, consider using simulation software to test your design.
• Document the simulation process and how it informed your design decisions.

How to Use in IA

• Reference this study when discussing the use of simulation or modelling techniques to evaluate design performance, especially for custom or biomechanically sensitive products.

Examiner Tips

• Demonstrate an understanding of how simulation tools can be used to validate design choices and predict performance under specific conditions.

Independent Variable: Integration of biomechanical simulation into AM workflow.

Dependent Variable: Design cycle time, product performance (comfort, function).

Controlled Variables: Scanning accuracy, material properties, simulation software fidelity.

Strengths

• Provides a comprehensive overview of AM in prosthetics/orthotics.
• Proposes a practical, integrated framework for design and evaluation.

Critical Questions

• What are the specific computational tools and biomechanical metrics most critical for success in this domain?
• How can the proposed framework be adapted for different types of assistive devices or patient needs?

Extended Essay Application

• Investigate the application of specific simulation software (e.g., FEA) to model the biomechanical performance of a custom-designed assistive device, comparing simulated results with theoretical expectations or limited physical testing.

Source

A Review of the Application of Additive Manufacturing in Prosthetic and Orthotic Clinics from a Biomechanical Perspective · Engineering · 2020 · 10.1016/j.eng.2020.07.019