The quickest and most affordable prototyping method is 3D printing the shin brace. PETG is the material of choice, given its strength, impact resistance, elasticity and affordability. It also offers excellent layer adhesion, reduced shrinkage and warp resistance during printing. The recommended process of prototyping the shin brace is as follows:

• Load the G-code of the sliced 3D CAD design into the 3D printer.
• Heat the bed to about 65 – 95 degrees Celsius. A rough build plate is recommended for base attachment to the bed. Ensure it is clean and level.
• Set the printing temperature to a temperature in the range between 235 – 250 degrees Celsius (Airwolf 3D, 2015).
• Recommended printing speed is about 60mm/s or lower.
• The travel speed can be as fast as 120mm/s.
• Maintain a low nozzle height. 0.1 mm is ideal.

Commercially available polyurethane straps can be used for fastening the shin brace onto the subject’s leg.

References

Airwolf 3D. (2015, December 5). 3D Printing with PETG Information | Tips & Tricks. 3D Printer Manufacturers - Airwolf 3D. https://airwolf3d.com/2015/12/05/3d-printing-with-petg-tips-and-tricks/