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Ankle–foot orthoses (AFOs) are assistive devices prescribed for a number of physical and neurological disorders affecting the mobility of the lower limbs. Additive manufacturing has been explored as an alternative process; however, it has proved to be inefficient cost-wise. This work aims to explore the possibilities of generating modular AFO elements, namely, calf, shank and footplate, with the localized composite reinforcement that aids in the optimization of the device in terms of functionality, aesthetics, rigidity and cost.

The conventional lower leg–foot orthosis configuration depends on thermoforming a polymer sheet around a mortar cast with a trademark firmness relying upon the trim-line with the inalienable plan restrictions. In manufacturing of AFO the expert, i.e. orthotist's, guidance is used. Polypropylene and polyethylene material is used in fabrication of AFO to complete all-round reported points of interest over the ordinary outlines, yet their mechanical conduct under administration conditions cannot be effectively anticipated.

AFOs made of polypropylene and polyethylene material are available in the market, which are used by children of age 3-5 years. With the existing AFO design, patients are facing excessive heating and sweating problems during long-term usage. After feedback from patients and orthotists (who prescribed AFO to patients), an attempt has been made to solve the problem with a new and improved AFO design of AFO by using finite element modelling and stress analysis. Also, the results indicate that the new design is similar to the actual product design.

This work introduces the low-cost 3D printing with reinforcement approach as an alternative route for the designing and manufacturing of orthotic devices with complex shapes. It is expected that new applications add-up to increase the body of knowledge about the behaviour of such products which will mix both areas, composite theory and additive manufacturing. This study investigated the fields related to 3D scanning, 3D printing and computer-aided designing for the manufacturing of a customized AFO.

The purpose of this study is improvement of human gait by customized design of ankle foot orthosis (AFO). An has been the most frequently used orthosis in children with cerebral palsy. AFOs are designed to boost existing features or to avoid depression or traumatize muscle contractures. The advantages of AFO’s utilized for advancement in human walk attributes for the improvement in foot deformities patients or youngsters with spastic loss of motion. In this research on the customized design of AFO's to improve gait, there are limitations during walking of foot drop patients. In children with foot drops, specific AFOs were explicitly altered to improve parity and strength which are beneficial to walking positions.

This study proposes the customized design of AFOs using computerized and additive manufacturing for producing advances to alter the design and increase comfort for foot drop patients. Structuring the proposed design fabricated by using additive manufacturing and restricted material, the investigation was finalized at the Design Analysis Software (ANSYS). The system that performs best under investigation can additionally be printed using additive manufacturing.

The results show that the customized design of AFOs meets the patient’s requirements and could also be an alternative solution to the existing AFO design. The biomechanical consequences and mechanical properties of additive manufactured AFOs have been comparable to historically synthetic AFOs. While developing the novel AFO designs, the use of 3D printing has many benefits, including stiffness and weight optimization, to improve biomechanical function and comfort. To defeat the issues of foot drop patients, a customized AFO is used to improve the human gait cycle with new material and having better mechanical properties.

This research work focuses on the biomechanical impacts and mechanical properties of customized 3D-printed AFOs and compares them to traditionally made AFOs. Customized AFO design using 3D printing has numerous potential advantages, including new material with lightweight advancement, to improve biomechanical function and comfort. Normally, new applications mean an incremental collection of learning approximately the behavior of such gadgets and blending the new design, composite speculation and delivered substance production. The test results aim to overcome the new AFO structure issues and display the limited components and stress examination. The outcome of the research is the improved gait cycle of foot drop patients.

The purpose of the study is to fabricate a joint between two aluminium metal matrix composites using microwave hybrid heating (MHH).

Taguchi design of experiments was applied to conduct the experimental study. The mechanical properties such as ultimate tensile strength, micro-hardness and porosity were studied. Grey Relational Analysis was applied to understand the significance of fabrication parameters of best performing sample. The dominant factor of fabrication was analysed using ANOVA. The best performance sample was further characterised using X-ray diffraction and field emission scanning electron microscopy. Energy dispersive X-ray was used to analyse the elemental composition of the sample.

The Aluminium Metal Matrix Composite (AMMC) joint was successfully fabricated using MHH. The mechanical properties were mainly influenced by the fabrication factor of exposure time.

The formation of AMMC joint using MHH might explore the way for the industries in the field of joining.