An orthosis is an external force system applied to a segment of the body to control motion, improve gait and correct or prevent deformity. Ankle-foot orthoses (AFO) are among the most commonly prescribed lower limb orthoses and are used for various lower limb impairments. They are commonly prescrribed solutions for individuals with foot drop to support weakened dorsiflextion muscles. As the number of rehabilitation treatments increases every year and orthotics services play an essential role in enabling quality life for people with disabilities, we want to replace or improve current conventional manufacturnig process, which is time-consuming, expensive and deficient. Presented manufacturing process is based on rapid prototyping (RP) techniques. The process is engineered to utilize surface data, of the patient anatomy as a digital input, which is captured with 3D scanning or CT imaging techniques. By using computer aided design (CAD) software, we generate direct lower limb model. In most cases, while capturing anatomical surfaces, the limb is not in a neutral position and it needs to be oriented based on the knowledge of biomechanics. The following is a description of the 3D modeling process, which can later be used as a base for additive manufacturing (AM). Use of digital technologies in the field of orthotics can later be upgraded with full automation process, which offers the possibility and conceptual direction for further work.
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