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FEA can also predict stress distribution and material deformation patterns and can determine the orthosis dimensions needed to mimic design characteristics of commercial orthoses. In the field of prosthetics and orthotics, FEA has been used to evaluate and design a variety of devices.

FEA of CAD models enables prediction of in situ stresses and strains through the application of boundary conditions that mimic real-world conditions. A fully parameterized computer-aided design (CAD) model uses a discrete set of parameters to fully describe and control a model's design. Recently, researchers have used finite element analysis (FEA) modeling to simulate and optimize novel AFO designs. In order to reduce the CF AFO refabrication rate and optimize user performance, both computational modeling and validation with experimental testing are needed to allow orthotists and researchers to design and optimally fabricate proper CF AFOs for their patients.

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Often, lack of knowledge about the interaction between CF AFO material properties, orthosis design, and patient-specific characteristics prevent some patients from experiencing the full benefits of the power restoration potential without design modifications requiring refabrication. Unlike thermoplastic AFOs, CF AFOs cannot be remolded if modifications are required. Multiple design modifications are often required to produce an AFO that is comfortable and results in improved gait performance. However, CF AFOs are difficult and expensive to fabricate. Studies have shown that CF AFOs improve ankle plantar-flexor power, plantar-flexor ankle joint moment, walking speed, and stride length and decrease energy cost compared with AFOs. Composite materials, such as carbon fiber (CF), have been suggested as an alternative to thermoplastics. Posterior leaf spring (PLS) AFOs have been made of thermoplastics due to easy molding and rapid fabrication, but these orthoses have very low energy storage and energy return capabilities and thus are unable to assist with propulsion during walking. Ankle-foot orthoses (AFOs) mechanically assist patients with gait impairments by improving limb control and joint positioning. In the United States, approximately 866,000 people use a lower-limb orthosis to assist them in daily activities. Key words: ankle-foot orthosis, boundary condition, carbon fiber, computed tomography, energy return, finite element analysis, fracture, mechanical property, posterior leaf spring, thermoplastic.

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We conclude that highly accurate FEA models will allow orthotists to improve CF AFO fabrication without wasting resources (time and money) on trial and error fabrications that are expensive and do not consistently improve AFO and user performance. The relative error of the energy return ratio predicted by the CF AFO FEA model developed in this study is less than 3%. The simulation results showed that FEA models produced accurate predictions for both types of orthoses. The actual mechanical testing demonstrated that CF performs better than thermoplastic. The FEA models were validated by comparing model predictions with mechanical testing data performed under the same loading and boundary conditions. Three AFOs, two made of CF composite material and one made of thermoplastic material, were fabricated and then mechanically tested to produce force-displacement data. Finite element analysis (FEA) models were developed to predict the mechanical behavior of AFOs in this study. However, fabricating a CF AFO to optimize the performance of the individual user may require multiple AFOs and expensive fabrication costs. Louis, MOĪbstract - Carbon fiber (CF) ankle-foot orthoses (AFOs) can improve gait by increasing ankle plantar-flexor power and improving plantar-flexor ankle joint moment and energy efficiency compared with posterior leaf spring AFOs made of thermoplastic. Louis, MO 4Mallinckrodt Institute of Radiology and 5Department of Orthopaedic Surgery, Washington University School of Medicine, St. Louis, MO 2College of Power and Energy Engineering, Harbin Engineering University, Harbin, China 3Orthotic & Prosthetic Design, St.

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