Award Title: 3D Printing Imperceptible Orthoses with Biomimetic Geometry and Molecular Structure to Enable Healthy Gait
Funder: The Academy of Medical Sciences

Abstract: This project will develop a novel kind of orthosis that is almost imperceptible yet enables healthy gait in UK and Zambian patients suffering from foot drop and ankle sprain. 20-33% of people suffer from a musculoskeletal condition. Up to 5m people develop foot drop every year due to stroke. Ankle sprain is the most common exercise-related injury. Orthoses are external devices that can significantly ameliorate these conditions by supporting the limbs or spine. Existing orthoses, however, suffer from three limitations: 1) compliance- patients may not wear orthoses due to discomfort; 2) dependency- orthoses prevent muscle use, leading to atrophy; 3) availability- patients in developing countries often cannot access orthoses. 3D printing offers control over geometry, material composition, and processing conditions at every point in an object, potentially leading to better medical devices by enabling them to mimic individual patientsâ€™ bodies. 3D printing could also widen access by manufacturing orthoses locally. Existing 3D printed orthoses, though, are uncomfortable because they are bulky, tightly grip limbs, and immobilize joints. Here, novel high stiffness & strength polymers will be integrated with flexible elastomers into computationally-designed architectures that are only tight when necessary and allow free ankle movement while preventing overextension. The resulting orthoses will provide protection, prevent atrophy, and enable healthy gait but be almost imperceptible to the wearer, increasing compliance. The team will work with hospitals in the UK and Zambia to ensure that devices meet local patient needs at appropriate cost and to carry out clinical trials.

Lay Abstract: This project will develop a new kind of orthosis that is almost imperceptible yet enables healthy walking in UK and Zambian patients suffering from ankle sprain and foot drop (where the forefoot cannot be raised making walking difficult and falls more likely). 20-33% of people suffer from a musculoskeletal condition. Up to 5m people develop foot drop every year due to stroke. Ankle sprain is the most common exercise-related injury. Orthoses are external devices that can make these conditions easier to live with by supporting the limbs or spine. Existing orthoses, however, suffer from three limitations: 1) patients may not wear them due to discomfort, leading to injury; 2) orthoses prevent muscle use, leading it to waste away and making people dependent on the orthosis 3) orthoses are often not available in developing countries. 3D printing enables production of very complex structures, potentially leading to better medical devices by enabling them to mimic patientsâ€™ bodies. 3D printing could also widen availability by manufacturing orthoses locally. Existing 3D printed orthoses, though, are uncomfortable because they are bulky, tightly grip limbs, and immobilize joints. Here, new complex orthoses will be 3D printed that are only tight when necessary and allow free ankle movement while preventing overextension. The resulting orthoses will provide protection and allow healthy walking, but be almost imperceptible to the wearer, increasing comfort. The team will work with hospitals in the UK and Zambia to ensure devices meet local patient needs at appropriate cost, and to trial devices with patients.

Research Activity Codes: 5.3 MEDICAL DEVICES
Health Categories: MUSCULOSKELETAL