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This research aims to focus on developing a customized support surface using additive manufacturing (AM) for effective pressure relief for patients who are in bed or wheelchair suffering from pressure ulcers (PU).

A novel customized support surface is developed using AM technology incorporated with magnetic levitation and ball and socket mechanisms. Magnetic levitation provides cushioning effect for the developed cushion to users who are sitting in a wheelchair and increases the rate of healing. The ball and socket mechanism provides the user body's self-adaptive mechanism and reduces shear and friction forces between the surfaces of the additive manufactured cushion and the human buttocks.

From the results of ISO 16480-6 biomechanical standardized tests, the additive manufactured support surface performed better than, or on par with, the most widely available commercial cushions. It is evident that the developed cushion’s peak pressure values are lower when compared with other cushions. The overall efficiency of the developed cushion was qualitatively reported; 67% of people felt it was excellent and 22% of people responded as good and 11% were satisfactory. Henceforth, the overall effectiveness of the developed support surface provides a better experience to the end-user in the view of PU reduction.

A developed additive manufactured customized support surface will be an alternative approach for the reduction of PU, and it overcomes the drawbacks faced by the currently available cushions.

This paper aims to develop a customized orthosis for treating congenital talipes equinovarus (clubfoot) deformity. Complications from non-surgical treatment method such as Ponseti method leads to relapse/recurrence of the foot after treated.

An alternate approach for treating clubfoot deformity can be seen as a viable approach to overcome the above-mentioned difficulties. Customized orthosis is designed and developed for a subject affected with right clubfoot deformity through fused deposition modeling of additive manufacturing (AM) technology with ABS plastic as base material. A unique mechanism is used to develop customized orthosis for achieving rotation of the foot along the three axis and range of motions.

Developed orthosis is incorporated with a unique mechanism that can be rotated and arrested at the specified angle along the three principle ranges of motion of the foot. Overall weight of the developed customized orthosis achieved is about 284 g, which has a significant 25 per cent reduction in weight when compared to traditional Ponseti casting method. Overcoming the difficulties faced in Ponseti method, customized orthosis can be an alternative method for treating clubfoot.

Developed orthosis will be an alternative approach for treating clubfoot deformity, and it overcomes the drawbacks faced by Ponseti method.