Enhancing Mobility for elderly stroke survivors using 3D printed custom made ankle foot orthotics.
Lead Research Organisation:
University of Derby
Department Name: College of Science & Engineering
Abstract
There are over 1.2 million stroke survivors in the UK with approximately 60% aged 65 years or over. One of the disabilities that they have, is lower limb weakness, which reduces their mobility significantly. Ankle foot orthotics (AFOs) provided by the NHS help manage the symptom. However, there is a 4 -12 weeks wait before they can receive a custom-made AFO, which is clinically more effective than off-the-shelf AFOs. This is because of the process used, to capture the shape of the ankle-foot (Plaster casting - Labour-intensive) and then to manufacture the AFO (Moulding - Labour-intensive), is time consuming. Furthermore, the material used for the AFOs are plastic-based which destroys the environment. The proposed idea is to recruit elderly stroke patients, assess their needs with respect to mobility and make a priority list of those needs. Then, their ankle-foot section will be 3D scanned which is an automated shape-capture process. This is currently done by <3% of NHS Trusts. The resulting custom designed AFO will then be 3D printed, which is an automated manufacturing process, using a zero-carbon material made from castor oil. The wait time to receive an AFO will be reduced to <5days. The aim of this work is to increase the mobility of elderly stroke patients at the earliest time possible. This will enhance the quality of life of those patients, both physically and mentally. Below is an illustrative summary.
Publications
Gunputh U
(2023)
Effect of Powder Bed Fusion Laser Sintering on Dimensional Accuracy and Tensile Properties of Reused Polyamide 11
in Polymers
| Description | The following has been achieved: 1. Enhanced understanding from ankle foot orthotics users and prescribers, about the process of getting and ankle foot orthosis and the different types of orthosis present from engagement workshops. 2. Definition of the limit to reusing polyamide 11, PA11 powder in a selective laser sintering process due to chemical changes in the powder and mechanical properties deterioration in the 3d printed product. 3. Understand the different refresh rate of PA11 powder in the selective laser melting process - Paper being developed. 4. Understanding the effect of artificially ageing PA11 samples in UV, humidity and high temperature (sweat mimicking) on the mechanical properties of the latter material - Another paper being developed |
| Exploitation Route | The outcomes of this funding gives people an opportunity to understand the effect of using plant based material in a powder based 3d printing system. It provides a clear picture on the sustainable manufacturing of bespoke devices such as an orthotics device. |
| Sectors | Energy Healthcare Manufacturing including Industrial Biotechology |
| Description | The outcome of this project resulted into the development of a new research area within University of Derby in collaboration with Royal Derby Hospital: Sustainable Manufacturing of functional prosthetic sockets for major lower limb amputee. Using the science behind the 3d printing of plant based polyamide powder and reusing the used powder, and patient's and prosthetist's input, concepts around the design of functional sockets are being worked on. |
| First Year Of Impact | 2023 |
| Sector | Energy,Healthcare,Manufacturing, including Industrial Biotechology |
| Impact Types | Societal |
| Description | Enhancing Mobility of Elderly Stroke Patients using sustainable solution |
| Amount | £102,480 (GBP) |
| Funding ID | ES/Y007654/1 |
| Organisation | Economic and Social Research Council |
| Sector | Public |
| Country | United Kingdom |
| Start | 08/2023 |
| End | 02/2024 |
| Description | UHDB and UoD AFO Project collaboration |
| Organisation | University Hospitals of Derby and Burton NHS Foundation Trust |
| Country | United Kingdom |
| Sector | Public |
| PI Contribution | The clinical scientist and deputy general Manager, Therapies and specialist rehabilitation from Royal Derby Hospital, Dr. Steve Attfield, came to us with a problem in the manufacturing of orthotics devices. At the University of Derby (UoD), we analysed the current design and manufacturing process and alternative design and manufacturing processes available. We developed a digitalised manufacturing workflow which involved 3d scanning of patient's foot, design of bespoke ankle foot orthosis and 3d printing of ankle foot orthosis. The UoD team brought forward test plans, options for materials and different ways forward. All research work, test plans and protocols, and grant funding application was done by UoD to support this collaboration. Mechanical testing of as built and artificially aged (UV, Humidity, temperature rise) petroleum (PA12) and plant based (PA11) 3d printed polyamides were performed on test samples. Testing on whole ankle foot orthoses were performed following which the AFO was tried by the volunteer and assessed with respect to fit and comfort and gait analysis. UV source, oven, powder based 3d printers [Formlab Fuse 1], Shimadzu Universal Tester, Vicon 3D motion capture system, kistler force plates, quintic high speed cameras, optojump software, solidworks software were used in this collaborative work. Our expertise in product design and development, 3d printing, mechanical testing, artificial ageing was used. |
| Collaborator Contribution | Royal derby hospital confirmed the design of ankle foot orthosis that was made, the feasibility of adopting new materials for this purpose and testing needed for clinical efficacy. They also provided us with NHS plastic based ankle foot orthosis to compare gait and motion data and donning and doffing process. They supported UoD by reviewing results and supporting us to interprete the results. |
| Impact | This collaboration is multidisciplinary involving clinical team, engineers and professors from Biomedical science, Exercise science, product design and manufacturing, mechanical engineering and human factors [psychology]. |
| Start Year | 2022 |
| Description | Patient group workshops |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | Local |
| Primary Audience | Patients, carers and/or patient groups |
| Results and Impact | 11 Foot orthotics users and 4 practitioners participated in the in-person and online workshops organised by the University of Derby. This increased our knowledge on orthotics users and prescribers to understand the actual challenges faced by them which was not limited to what we were initially aware of. This process is ongoing and the aim is to work collaboratively with users and practitioners on this project. |
| Year(s) Of Engagement Activity | 2023,2024 |