U.S. patent application number 17/547502 was filed with the patent office on 2022-06-16 for additive manufacturing techniques for orthotics.
This patent application is currently assigned to Hanger, Inc.. The applicant listed for this patent is Hanger, Inc.. Invention is credited to Antonio Dias, Aaron Flores, Justin Mieth.
Application Number | 20220183871 17/547502 |
Document ID | / |
Family ID | |
Filed Date | 2022-06-16 |
United States Patent
Application |
20220183871 |
Kind Code |
A1 |
Flores; Aaron ; et
al. |
June 16, 2022 |
ADDITIVE MANUFACTURING TECHNIQUES FOR ORTHOTICS
Abstract
An orthotic device for a patient's foot includes a shell that is
configured to structurally support the patient's foot. The shell
has a variable thickness along a dimension of the shell. The shell
is configured to undergo flexion throughout the shell. The variable
thickness of the shell targets areas of increased stress.
Inventors: |
Flores; Aaron; (Austin,
TX) ; Dias; Antonio; (Scottsdale, AZ) ; Mieth;
Justin; (Austin, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hanger, Inc. |
Austin |
TX |
US |
|
|
Assignee: |
Hanger, Inc.
Austin
TX
|
Appl. No.: |
17/547502 |
Filed: |
December 10, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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63124230 |
Dec 11, 2020 |
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International
Class: |
A61F 5/14 20060101
A61F005/14; B33Y 50/00 20060101 B33Y050/00; B33Y 80/00 20060101
B33Y080/00 |
Claims
1. An orthotic device for a patient's foot, the orthotic device
comprising: a shell configured to structurally support the
patient's foot, the shell having a variable thickness along a
dimension of the shell; wherein the shell is configured to undergo
flexion throughout the shell; wherein the variable thickness of the
shell targets areas of increased stress.
2. The orthotic device of claim 1, wherein the orthotic device is a
shoe insert configured to be worn on the patient's foot.
3. The orthotic device of claim 1, wherein the shell is configured
to completely contain a heel of the patient's foot.
4. The orthotic device of claim 1, wherein the shell is configured
to provide medial support for the patient's foot.
5. The orthotic device of claim 1, wherein the shell is configured
to provide lateral support for the patient's foot.
6. The orthotic device of claim 1, wherein the shell is configured
to undergo deformation without sustaining structural damage.
7. The orthotic device of claim 1, wherein a thickness of the shell
at a first longitudinal position of the shell is different than a
thickness of the shell at a second longitudinal position of the
shell.
8. The orthotic device of claim 1, wherein the variable thickness
is configured to accommodate for differences in an anatomical
structure of the patient's foot.
9. The orthotic device of claim 1, wherein the orthotic device is
configured for use with a patient having valgus of the patient's
foot, the shell configured to provide gradual offset to an anatomy
of the patient's foot.
10. The orthotic device of claim 1, wherein the orthotic device is
configured for use with a patient having varus of the patient's
foot, the shell configured to provide gradual offset to an anatomy
of the patient's foot.
11. The orthotic device of claim 1, wherein a geometric shape and
the variable thickness of the shell are configured to account for
unique anatomical structure of the patient's foot to relieve stress
along edges, sides, and a bottom of the patient's foot.
12. A method for manufacturing an orthotic device for a patient's
foot, the method comprising: using a digital scanner to capture an
anatomical structure of the patient's foot and generate a patient
scan file; modifying the patient scan file into a device shape;
creating a printer-compatible file for an additive manufacturing
device; and additively manufacturing the printer-compatible file
using the additive manufacturing device to generate the orthotic
device.
13. The method of claim 12, wherein the device shape is a schematic
of the orthotic device.
14. The method of claim 13, further comprising: converting the
schematic of the orthotic device that captures the anatomical
structure of the patient's foot to a computer assisted design (CAD)
file or a computer assisted manufacturing (CAM) file.
15. The method of claim 12, wherein modifying the patient scan file
comprises: using at least one of a buildup technique or a reduction
technique to generate the printer-compatible file so that the
printer-compatible file accommodates the anatomical structure of
the patient's foot.
16. The method of claim 12, wherein additively manufacturing the
printer-compatible file comprises: providing layers of material on
top of each other in succession to produce the orthotic device.
17. An orthotic device for a patient's foot manufactured using
additive manufacturing, the orthotic device comprising: a shell
configured to structurally support the patient's foot, the shell
having a variable thickness along a dimension of the shell; wherein
the variable thickness of the shell increases at areas of increased
stress.
18. The orthotic device of claim 17, wherein the shell is
configured to undergo flexion throughout the shell.
19. The orthotic device of claim 17, wherein the orthotic device is
configured for use with a patient having valgus of the patient's
foot, the shell configured to provide gradual offset to an anatomy
of the patient's foot.
20. The orthotic device of claim 17, wherein the orthotic device is
configured for use with a patient having varus of the patient's
foot, the shell configured to provide gradual offset to an anatomy
of the patient's foot.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This application claims the benefit of and priority to U.S.
Provisional Application No. 63/124,230, filed Dec. 11, 2020, the
entire disclosure of which is incorporated by reference herein.
BACKGROUND
[0002] The present disclosure relates generally to prosthetics and
orthotics. More particularly, the present disclosure relates to
additive manufacturing or protective devices, prosthetics and/or
orthotics.
SUMMARY
[0003] One embodiment of the present disclosure is an orthotic
device for a patient's foot, according to some embodiments. In some
embodiments, the orthotic device includes a shell that is
configured to structurally support the patient's foot. In some
embodiments, the shell has a variable thickness along a dimension
of the shell. In some embodiments, the shell is configured to
undergo flexion throughout the shell. In some embodiments, the
variable thickness of the shell targets areas of increased
stress.
[0004] In some embodiments, the orthotic device is a shoe insert
configured to be worn on the patient's foot. In some embodiments,
the shell is configured to completely contain a heel of the
patient's foot. In some embodiments, the shell is configured to
provide medial support for the patient's foot.
[0005] In some embodiments, the shell is configured to provide
lateral support for the patient's foot. In some embodiments, the
shell is configured to undergo deformation without sustaining
structural damage.
[0006] In some embodiments, a thickness of the shell at a first
longitudinal position of the shell is different than a thickness of
the shell at a second longitudinal position of the shell. In some
embodiments, the variable thickness is configured to accommodate
for differences in an anatomical structure of the patient's
foot.
[0007] In some embodiments, the orthotic device is configured for
use with a patient having valgus of the patient's foot, the shell
configured to provide gradual offset to an anatomy of the patient's
foot. In some embodiments, the orthotic device is configured for
use with a patient having varus of the patient's foot, the shell
configured to provide gradual offset to an anatomy of the patient's
foot. In some embodiments, a geometric shape and the variable
thickness of the shell are configured to account for unique
anatomical structure of the patient's foot to relieve stress along
edges, sides, and a bottom of the patient's foot.
[0008] Another implementation of the present disclosure is a method
for manufacturing an orthotic device for a patient's foot,
according to some embodiments. In some embodiments, the method
includes using a digital scanner to capture an anatomical structure
of the patient's foot and generate a patient scan file. In some
embodiments, the method also includes modifying the patient scan
file into a device shape, creating a printer-compatible file for an
additive manufacturing device, and additively manufacturing the
printer-compatible file using the additive manufacturing device to
generate the orthotic device.
[0009] In some embodiments, the device shape is a schematic of the
orthotic device. In some embodiments, the method further includes
converting the schematic of the orthotic device that captures the
anatomical structure of the patient's foot to a computer assisted
design (CAD) file or a computer assisted manufacturing (CAM)
file.
[0010] In some embodiments, modifying the patient scan file
includes using at least one of a buildup technique or a reduction
technique to generate the printer-compatible file so that the
printer-compatible file accommodates the anatomical structure of
the patient's foot. In some embodiments, additively manufacturing
the printer-compatible file includes providing layers of material
on top of each other in succession to produce the orthotic
device.
[0011] Another embodiment of the present disclosure is an orthotic
device for a patient's foot manufactured using additive
manufacturing, according to some embodiments. In some embodiments,
the orthotic device includes a shell configured to structurally
support the patient's foot, the shell having a variable thickness
along a dimension of the shell. In some embodiments, the variable
thickness of the shell increases at areas of increased stress.
[0012] In some embodiments, the shell is configured to undergo
flexion throughout the shell. In some embodiments, the orthotic
device is configured for use with a patient having valgus of the
patient's foot, the shell configured to provide gradual offset to
an anatomy of the patient's foot. In some embodiments, the orthotic
device is configured for use with a patient having varus of the
patient's foot, the shell configured to provide gradual offset to
an anatomy of the patient's foot.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The disclosure will become more fully understood from the
following detailed description, taken in conjunction with the
accompanying figures, wherein like reference numerals refer to like
elements, in which:
[0014] FIG. 1 is a front view of a foot orthotic device, according
to some embodiments.
[0015] FIG. 2 is a side view of the foot orthotic device of FIG. 1,
according to some embodiments.
[0016] FIG. 3 is a top view of the foot orthotic device of FIG. 1,
according to some embodiments.
[0017] FIG. 4 is a flow diagram of a process for manufacturing the
foot orthotic device of FIGS. 1-3, according to some
embodiments.
[0018] FIG. 5 is a system for additive manufacturing that can be
used to manufacture the foot orthotic device of FIGS. 1-3,
according to some embodiments.
DETAILED DESCRIPTION
[0019] Before turning to the FIGURES, which illustrate the
exemplary embodiments in detail, it should be understood that the
present application is not limited to the details or methodology
set forth in the description or illustrated in the FIGURES. It
should also be understood that the terminology is for the purpose
of description only and should not be regarded as limiting.
Overview
[0020] Referring generally to the FIGURES, additive manufacturing
is used to produce orthotic devices with variable wall thickness.
The variable wall thickness facilitates improved fit and comfort,
and can facilitate distribution of stresses. The foot orthotic
device is a shoe insert designed to stabilize and support the foot
to give to the wearer increased gait and general movement control,
according to some embodiments.
[0021] In some embodiments, the orthotic device has a variable
cross section thickness. The differing thickness of the orthotic
device is based on an anatomical foot structure of the patient,
according to some embodiments. In some embodiments, the varying
thickness provides flexibility in needed areas and increased
structural support in others.
[0022] In some embodiments, the orthotic device is produced using
additive manufacturing. The method of producing the device includes
taking a three dimensional file of the wearer's foot and applying
buildups and modifications to create a new computer assisted design
(CAD)/computer assisted manufacturing (CAM) schematic of the
device, according to some embodiments. The CAD/CAM schematic is
uploaded to the 3D printer where the device is constructed layer by
layer in accordance to the previously mentioned buildups and
modifications, according to some embodiments. The end result is a
foot orthotic with variable thickness that is configured to conform
to the anatomical structure of the patient, according to some
embodiments.
[0023] The techniques described herein for additive manufacturing
can additionally be used to manufacture the prosthetic, orthotic,
connection insert, or related medical devices as described in U.S.
Patent Application Pub. No.: 2018/0353308 A1, filed Jul. 31, 2018,
the entire disclosure of which is incorporated by reference herein.
Further, any of the additive manufacturing techniques as described
in U.S. Patent Application Pub. No.: 2018/0353308 A1 may be used to
manufacture any of the devices described herein.
[0024] In some embodiments, the prosthetic, orthotic, connection
insert, protective device, etc., as described herein are
manufactured using any of the techniques as described in U.S. Pat.
No.: 10,766,246 B2, filed Dec. 15, 2014, the entire disclosure of
which is incorporated by reference herein.
Orthotic Device
[0025] Referring particularly to FIGS. 1-3, an orthotic device, a
foot insert, a shoe insert, a foot orthotic device, etc., shown as
orthotic device 200 is shown, according to some embodiments.
Orthotic device 200 may be configured to stabilize and support a
patient's food to give the patient improved gait and movement
control. The orthotic device 200 can have a variable thickness
throughout. The variable or differing thickness of orthotic device
200 can be based on anatomical foot structure of the patient to
provide differing flexibility in required areas and improve
structural support in other areas. Orthotic device 200 can be
manufactured, fabricated, or constructed using additive
manufacturing techniques such as 3d printing.
[0026] Referring still to FIGS. 1-3, orthotic device 200 includes a
shell, a structural member, a sidewall, etc., shown as shell 201.
Shell 201 can be flexible throughout. In some embodiments, shell
201 has differing thicknesses or elasticities throughout. In some
embodiments, shell 201 is configured to receive a patient's foot so
that the patient's foot rests on top of the shell 201 with contours
of shell 201 aligning with contours of the patient's foot. For
example, shell 201 can include a heel portion 202 that is
configured to receive a patient's heel. Shell 201 can also include
a distal medial contour 206 that matches or corresponds to a distal
medial contour of the patient's foot. Shell 201 can also include a
distal lateral contour 204 that matches or corresponds to a distal
lateral contour of the patient's foot. Shell 201 can have an
overall length 208 that matches or corresponds to an overall length
of the patient's foot.
[0027] As shown in FIG. 3, shell 201 can also include flaring 214
on a front edge of a medial side 210 of shell 201. In some
embodiments, the flaring 214 is configured to conform to the first
metatarsal head of the patient's foot. The flaring 214 can be
adjusted or deformed plastically by applying heat and a force to
the shell 201.
[0028] Shell 201 can also include flaring 216 on a front edge of a
lateral side 212 of shell 201. In some embodiments, the flaring 216
is configured to conform to the fifth metatarsal head of the
patient's foot. The flaring 216 can be adjusted or deformed
plastically by applying heat and a force to the shell 201.
[0029] Shell 201 can also include a medial side arch portion 218
and a lateral side arch portion 220. In some embodiments, thickness
of shell 201 is targeted or adjusted (e.g., increased or decreased)
at the medial side arch portion 218 or the lateral side arch
portion 220 during design or manufacturing of shell 201. In this
way, shell 201 can have thickness at the medial side arch portion
218 or the lateral side arch portion 220 to provide a desired
amount of flexibility or support at these areas.
[0030] Referring particularly to FIG. 3, shell 201 can include a
thickness 222. The thickness 222 can be measured between an outer
periphery or an outer edge of shell 201 and an inner periphery or
an inner edge of shell 201 at a particular point. Shell 201 can
have a variable thickness 222 throughout. For example, the medial
side arch portion 218 and the lateral side arch portion 220 can
have increased thickness relative to the flaring 216, the flaring
214, etc. In some embodiments, the thickness 222 of different areas
or portions of shell 201 results in additional support or
flexibility of shell 201. For example, increased thickness of shell
201 may correspond to improved support, whereas areas with
decreased or lower thickness may undergo higher amounts of flexion.
The amount of flexion or deformation may be inversely proportional
to thickness 222.
[0031] In some embodiments, a geometry or thickness of shell 201 is
configured to target areas of high stress of the patient's foot.
For example, areas with higher stress may require additional
support and can therefore have added thickness. In some
embodiments, the geometry and/or thickness of shell 201 is
configured to distribute forces applied to shell 201 by the
patient's foot across an increased surface, thereby reducing
pressure at a single point. In some embodiments, the thickness can
be increased or decreased at different portions or areas of the
shell 201 during the design of shell 201 to target areas of
increased stress on the patient's foot. For example, the thickness
222 of the medial side 210 or the lateral side 212 of shell 201 may
be greater than other areas of shell 201 based on requirements of
the patient's foot. Similarly, contouring of the medial side 210
and/or the lateral side 212 can be configured based on requirements
of the patient's foot.
[0032] In some embodiments, different supporting portions of shell
201 have thickness 222 that is proportional to corresponding
anatomy of the patient's foot to relieve stress across the
patient's foot. The variable thickness 222 of shell 201 can provide
variable flexibility throughout shell 201. The shell 201 of
orthotic device 200 can be adjusted by applying heat and a force to
shell 201. For example, the overall length 208 of shell 201 can be
adjusted to fit the requirements of the patient's foot. Similarly,
dimensions of the heel portion 202 can be modified to fit the
requirements of the patient's foot. Similarly, any of a first
metatarsal head cutout or contour, a length from an apex of the
heel to the first metatarsal head cutout or contour, a fifth
metatarsal head cutout or contour, a length from the apex of the
heel to the fifth metatarsal head cutout or contour, a medial arch
cutout or contour, a lateral arch cutout or contour, a distal
medial contour, a distal lateral contour, a tapering amount of a
medial supporting vertical wall, or a tapering amount of a lateral
supporting vertical wall of shell 201 can correspond to, or be
adjusted (during design of shell 201) based on requirements of the
patient's foot.
[0033] In some embodiments, shell 201 is configured to provide
structural support to the patient's foot to supplement anatomical
structures of the patient's foot. In some embodiments, shell 201 is
configured to improve or increase support for the patient's foot by
relieving pressure from high stress areas of the patient's foot
using targeted increase and reductions in the thickness 222 of
shell 201. In some embodiments, shell 201 is configured for use
with a patient that has valgus of the foot by providing gradual
offset to account for excessive leaning of the patient's foot.
Similarly, shell 201 can be configured for use with a patient that
has varus of the foot by providing gradual offset to account for
excessive leaning of the patient's foot.
[0034] The shell 201 has thickness 222 that may transition between
different spatial locations along the shell 201. The thickness 222
of the shell 201 may be uniform or may vary spatially at different
positions. For example, areas of the shell 201 that are anticipated
or expected to undergo higher stress may have an increased
thickness relative to other areas that are expected to undergo
lower stress during use of the orthotic device 200 (or vice versa).
In some embodiments, different areas of the shell 201 that should
deform to a shape of the user's residual limb have a decreased
thickness to facilitate controlled flexing or bending of the shell
201 to facilitate comfort and proper fit of the shell 201. In some
embodiments, the thickness of the shell 201 increases from one end
to another end of the shell 201 so that the thickness of the shell
201 proximate the one end is greater than thickness of the shell
201 at the other end. In some embodiments, variation of the
thickness of the shell 201 is configured based on patient activity
level, weight, etc.
[0035] Referring now to FIG. 4, a process 800 for producing or
manufacturing the orthotic device 200 of FIGS. 1-3 is shown,
according to some embodiments. Process 800 includes steps 802-812
and can be performed using an additive manufacturing system (e.g.,
system 1300 as described in greater detail below with reference to
FIG. 5).
[0036] Process 800 includes scanning a patient's foot (step 802),
according to some embodiments. In some embodiments, step 802 is
performed using a scan device or a 3d scanner (e.g., scan device
1312 as described in greater detail below with reference to FIG.
5). In some embodiments, performing step 802 results in the
generation of a scan file.
[0037] Process 800 includes modifying a patient scan file into a
device shape (step 804), according to some embodiments. In some
embodiments, the device shape is a schematic of the orthotic
device. For example, step 804 can include receiving one or more
user inputs (e.g., from a health care provider) to adjust the
thickness (e.g., increase or decrease the thickness) of a CAD file
at different areas or locations (e.g., at any of a first metatarsal
head cutout or contour, a length from an apex of the heel to the
first metatarsal head cutout or contour, a fifth metatarsal head
cutout or contour, a length from the apex of the heel to the fifth
metatarsal head cutout or contour, a medial arch cutout or contour,
a lateral arch cutout or contour, a distal medial contour, a distal
lateral contour, etc., of the CAD file or the patient scan file).
In some embodiments, step 804 includes adding or removing material
at any of the different areas to achieve a desired thickness. Step
804 can be performed by computer system 1302 of system 1300,
described in greater detail below with reference to FIG. 5.
[0038] Process 800 includes creating a printer-compatible file for
a device (e.g., the orthotic device 200) (step 806), according to
some embodiments. Process 800 also includes uploading the
printer-compatible file for the device to a printer (step 808),
according to some embodiments.
[0039] In some embodiments, steps 806 and 808 are performed by
computer system 1302 and 3d printer 1314 of system 1300 as
described in greater detail below with reference to FIG. 5.
[0040] Process 800 includes printing the printer-compatible file
for the device to generate a 3d printed device (e.g., orthotic
device 200) (step 810), according to some embodiments. Step 810 can
be performed by an additive manufacturing machine or 3d printer
1314 of system 1300 as described in greater detail below with
reference to FIG. 5. In some embodiments, step 810 includes
performing additive manufacturing (e.g., dispensing or outputting
layers consecutively on top of each other) to produce the device.
In some embodiments, the additive manufacturing is performed using
a single uniform material such as a thermoplastic (e.g., nylon).
The resulting device or 3d printed component can have variable
thickness as defined by the printer-compatible file.
[0041] Process 800 incudes performing post-processing of the 3d
printed device (step 812), according to some embodiments. For
example, step 812 can include removing excess material that is
dispensed during step 810 (e.g., during fabrication of the device).
Step 812 can include applying heat to plastically deform the 3d
printed device. Step 812 can be performed by a technician.
Additional post-processing can be performed based on anatomy or
needs of the patient.
Additive Manufacturing System Architecture
[0042] Referring now to FIG. 5, a system 1300 for additive
manufacturing of prosthetic, orthotic, or protective devices is
shown, according to some embodiments. System 1300 includes a user
device 1310, a display device 1316, a computer system 1302, a scan
device 1312, and a 3d printer or additive manufacturing machine
1314.
[0043] Computer system 1302 is configured to receive scan data from
scan device 1312, according to some embodiments. Computer system
1302 can be a desktop computer, a laptop, a remote computing
system, a smart phone, a tablet, a personal computing device, etc.
Computer system 1302 includes a processing circuit 1304 having
memory 1308 and a processor 1306. Processor 1306 can be implemented
as a general-purpose processor, an application specific integrated
circuit (ASIC), one or more field programmable gate arrays (FPGAs),
a group of processing components, or other suitable electronic
processing components.
[0044] Memory 1308 (e.g., memory, memory unit, storage device,
etc.) may include one or more devices (e.g., RAM, ROM, Flash
memory, hard disk storage, etc.) for storing data and/or computer
code for completing or facilitating the various processes, layers
and modules described in the present application. Memory 1308 may
be or include volatile memory or non-volatile memory. Memory 1308
may include database components, object code components, script
components, or any other type of information structure for
supporting the various activities and information structures
described in the present application. According to an exemplary
embodiment, memory 1308 is communicably connected to processor 1306
via processing circuit 1304 and includes computer code for
executing (e.g., by processing circuit 1304 and/or processor 1306)
one or more processes described herein.
[0045] Computer system 1302 can be configured to run CAD computer
software to facilitate the design and production of any of
prosthetic socket 100, orthotic device 200, and/or protective
device 300. Computer system 1302 is configured to receive scan data
from scan device 1312, according to some embodiments. In some
embodiments, the scan data is a scan file obtained from scan device
1312. In some embodiments, a technician may scan device 1312 to
scan a patient's residual limb or a cast of the patient's residual
limb, thereby generating the scan data.
[0046] When the scan data is provided to computer system 1302,
computer system 1302 can generate a CAD or CAM file. A user (e.g.,
a health care provider) can then provide inputs (e.g., via user
device 1310) to adjust geometry, thickness, etc., of the CAD or CAM
file. More generally, computer system 1302 may use the scan data to
generate a digital representation of a device to be manufactured
for the patient's residual limb. Computer system 1302 can provide
display data to display device 1316 (e.g., a computer screen, a
display screen, etc.) so that the digital representation is
visually displayed in real-time. The user or health care provider
can then view real-time changes or updates as the user changes or
adjusts the CAD or CAM file.
[0047] For example, the user may adjust the CAD or the CAM file so
that the design gradually tapers or thickens in different areas. In
some embodiments, the user or the health care provider may use data
from different experiments to identify areas where a patient may
experience high stress. The user may decrease thickness of the CAD
or CAM file at areas where high stress is experienced so that the
3d printed device may flex or deform. This can allow the 3d printed
device to be more comfortable for the patient. In some embodiments,
thickness of the 3d printed devices is maintained above a minimum
thickness value. The user can also use knowledge regarding
different weight lines of the patient to determine which areas of
the CAD or CAM file/model should have decreased or increased
thickness. The user may also use historical data to determine which
areas or portions of the 3d printed device or the CAD/CAM
file/model should have increased or decreased thickness (e.g., wall
thickness).
[0048] Once the user (e.g., the health care provider) has adjusted
or manipulated the CAD/CAM file/model, the user can prompt computer
system 1302 to export the file/model to 3d printer 1314 as print
data. Computer system 1302 can convert the adjusted, manipulated,
or updated CAD/CAM file/model to a file type that is compatible
with 3d printer 1314 (e.g., a Standard Tessellation Language (STL)
file). Computer system 1302 then provides the print data to 3d
printer 1314.
[0049] The 3d printer 1314 can be any additive manufacturing
machine or device that is configured to successively provide or
discharge layers of material onto each other to form or construct a
part. 3d printer 1314 may be configured to dispense material (e.g.,
one or more powder materials that can form nylon when combined with
fusing/detailing agents and exposed to fusing light, or any other
dispensable materials) in layers to fabricate the CAD/CAM file.
[0050] Advantageously, the systems and methods described herein can
be used to produce 3d printed prosthetics, orthotics, or protective
devices. Traditional molding methods do not offer the same
flexibility of variable wall thickness as does additive
manufacturing. The variable wall thickness is achieved using
additive manufacturing (e.g., 3d printing) and can facilitate
improved fit, comfort, and stress distribution.
Configuration of Exemplary Embodiments
[0051] As utilized herein, the terms "approximately", "about",
"substantially", and similar terms are intended to have a broad
meaning in harmony with the common and accepted usage by those of
ordinary skill in the art to which the subject matter of this
disclosure pertains. It should be understood by those of skill in
the art who review this disclosure that these terms are intended to
allow a description of certain features described and claimed
without restricting the scope of these features to the precise
numerical ranges provided. Accordingly, these terms should be
interpreted as indicating that insubstantial or inconsequential
modifications or alterations of the subject matter described and
claimed are considered to be within the scope of the invention as
recited in the appended claim.
[0052] It should be noted that the terms "exemplary" and "example"
as used herein to describe various embodiments is intended to
indicate that such embodiments are possible examples,
representations, and/or illustrations of possible embodiments (and
such term is not intended to connote that such embodiments are
necessarily extraordinary or superlative examples).
[0053] The terms "coupled," "connected," and the like, as used
herein, mean the joining of two members directly or indirectly to
one another. Such joining may be stationary (e.g., permanent, etc.)
or moveable (e.g., removable, releasable, etc.). Such joining may
be achieved with the two members or the two members and any
additional intermediate members being integrally formed as a single
unitary body with one another or with the two members or the two
members and any additional intermediate members being attached to
one another.
[0054] References herein to the positions of elements (e.g., "top,"
"bottom," "above," "below," "between," etc.) are merely used to
describe the orientation of various elements in the figures. It
should be noted that the orientation of various elements may differ
according to other exemplary embodiments, and that such variations
are intended to be encompassed by the present disclosure.
[0055] Also, the term "or" is used in its inclusive sense (and not
in its exclusive sense) so that when used, for example, to connect
a list of elements, the term "or" means one, some, or all of the
elements in the list. Conjunctive language such as the phrase "at
least one of X, Y, and Z," unless specifically stated otherwise, is
otherwise understood with the context as used in general to convey
that an item, term, etc. may be either X, Y, Z, X and Y, X and Z, Y
and Z, or X, Y, and Z (i.e., any combination of X, Y, and Z). Thus,
such conjunctive language is not generally intended to imply that
certain embodiments require at least one of X, at least one of Y,
and at least one of Z to each be present, unless otherwise
indicated.
[0056] It is important to note that the construction and
arrangement of the systems as shown in the exemplary embodiments is
illustrative only. Although only a few embodiments of the present
disclosure have been described in detail, those skilled in the art
who review this disclosure will readily appreciate that many
modifications are possible (e.g., variations in sizes, dimensions,
structures, shapes and proportions of the various elements, values
of parameters, mounting arrangements, use of materials, colors,
orientations, etc.) without materially departing from the novel
teachings and advantages of the subject matter recited. For
example, elements shown as integrally formed may be constructed of
multiple parts or elements. It should be noted that the elements
and/or assemblies of the components described herein may be
constructed from any of a wide variety of materials that provide
sufficient strength or durability, in any of a wide variety of
colors, textures, and combinations. Accordingly, all such
modifications are intended to be included within the scope of the
present inventions. Other substitutions, modifications, changes,
and omissions may be made in the design, operating conditions, and
arrangement of the preferred and other exemplary embodiments
without departing from scope of the present disclosure or from the
spirit of the appended claim.
* * * * *