Step 1: Capture the Foot Impression
Prepare the Foam Impression Box: Ensure that the foam impression box is clean and ready for use.
Take the Foot Cast: Have the patient step into the foam box to create an impression of their foot. Ensure that they apply even pressure to capture the foot's contours accurately.
Step 2: Measure Foot Dimensions
Measure Size and Arch Height: Use a ruler or measuring tape to determine key dimensions:
Length of the foot
Width at various points (forefoot, midfoot, heel)
Arch height from the ground to the apex of the arch
Record Measurements: Document these measurements for reference during design.
Step 3: Transfer Data to SolidWorks
Open SolidWorks: Launch the SolidWorks software on your computer.
Create a New Project: Start a new project for designing the orthosis components.
Input Measurements: Use the recorded dimensions to create a 3D model of:
The base plate
The heel cup
The arch support
Design Components: Ensure that each part fits well with respect to the patient's foot shape and arch height.
Step 4: Prepare for 3D Printing
Select Material: Choose PLA (Polylactic Acid) as your material for 3D printing due to its strength and ease of use.
Add Threaded Inserts: Design threaded inserts in your model where screws will be used to fasten components together.
Step 5: Print Components
Set Up 3D Printer: Load PLA filament into your 3D printer and configure settings for optimal printing quality.
Print Each Component: Print the base plate, heel cup, and arch support separately, ensuring that all parts are printed accurately.
Step 6: Post-Processing
Sand Rough Edges: After printing, use sandpaper to smooth out any rough edges on all components for comfort and aesthetics.
Clean Components: Remove any residual filament or debris from the printing process.
Step 7: Assemble the Orthosis
Connect Components:
Align the base plate with the heel cup and arch support.
Use screws to fasten these components together at designated threaded inserts.
Apply adhesive where necessary for added strength.
Install Velcro Straps:
Attach Velcro straps at three key locations: Forefoot
Ensure that straps are securely fastened but allow for adjustability.
Step 8: Add Cushioning
Choose Padding Material: Select silicone or foam padding based on patient comfort and pressure distribution needs.
Apply Padding:
Cut padding to fit areas prone to pressure (e.g., underfoot, around the heel).
Securely attach padding using adhesive or by integrating it into the design during assembly.
Final Inspection
Conduct a thorough inspection of the assembled orthosis to ensure all components are securely attached and that there are no sharp edges.
Test fit on the patient, making any necessary adjustments for comfort and functionality.