The possibility to realize highly customized orthoses is receiving boost thanks to the widespread diffusion of low-cost 3D printing technologies. However, rapid prototyping (RP) with 3D printers is only the final stage of patient personalized orthotics processes. A reverse engineering (RE) process is in fact essential before RP, to digitize the 3D anatomy of interest and to process the obtained surface with suitable modeling software, in order to produce the virtual solid model of the orthosis to be printed. In this paper, we focus on the specific and demanding case of the customized production of hand orthosis. We design and test the essential steps of the entire production process with particular emphasis on the accurate acquisition of the forearm geometry and on the subsequent production of a printable model of the orthosis. The choice of the various hardware and software tools (3D scanner, modeling software, and FDM printer) is aimed at the mitigation of the design and production costs while guaranteeing suitable levels of data accuracy, process efficiency, and design versatility. Eventually, the proposed method is critically analyzed so that the residual issues and critical aspects are highlighted in order to discuss possible alternative approaches and to derive insightful observations that could guide future research activities.

In the field of rehabilitation, the 3D scanning of body parts can be considered a crucial starting point for subsequent 3D model design of customised devices, especially when additive manufacturing techniques are involved in their production. This study experimentally evaluates and identifies appropriate procedures to acquire and process 3D anatomic images of the hand, including fingers, for the design of customised orthoses. Hand scanning is a complex activity and requires solutions capable of solving problematic aspects, such as the difficulty in maintaining the hand in a steady position and the presence of motion artefacts due to involuntary movements. We addressed such issues by considering the use of two different kinds of optical scanning device. The acquisition process has been initially defined based on healthy subjects and then extended to patients affected by pathologies that compromise upper limb functionality. Quality anatomical models were produced thanks to the application of advanced geometry processing technologies for the automated alignment of multiple scans and the removal of artefacts due to involuntary movements. As a result, with distinctive pros and cons, both the proposed combinations of scanning procedures and dedicated geometry processing evidenced their suitability in producing complete and accurate enough 3D models to be exploited for the subsequent design and production of customised hand orthoses in a typical reverse engineering pipeline.

In the rehabilitation field, the use of additive manufacturing techniques to realize customized orthoses is increasingly widespread. Obtaining a 3D model for the 3D printing phase can be done following different methodologies. We consider the creation of personalized upper limb orthoses, also including fingers, starting from the acquisition of the hand geometry through accurate 3D scanning. However, hand scanning procedure presents differences between healthy subjects and patients affected by pathologies that compromise upper limb functionality. In this work, we present the concept and design of a 3D printed support to assist hand scanning of such patients. The device, realized with FDM additive manufacturing techniques in ABS material, allows palmar acquisitions, and its design and test are motivated by the following needs: (1) immobilizing the hand of patients during the palmar scanning to reduce involuntary movements affecting the scanning quality and (2) keeping hands open and in a correct position, especially to contrast the high degree of hypertonicity of spastic subjects. The resulting device can be used indifferently for the right and the left hand; it is provided in four-dimensional sizes and may be also suitable as a palmar support for the acquisition of the dorsal side of the hand.

This paper describes a miniaturized electromechanical generator, integrable in a human total knee prosthesis, in which the mechanical energy, related to the knee joint movement, is converted into electrical energy. This device has been conceived in order to power an autonomous sensor system, integrated into the prosthesis, able to monitor the loads on the articular surfaces and to transmit those outside the body.