This article introduces a novel concept where advanced technologies have been leveraged to produce a modular walking orthosis (MOWA) within a completely digital process chain. All processes of this new supply chain are described step-by-step. The prescription and treatment of lower leg orthoses for individuals with paralysis or muscle weakness, particularly cerebral palsy (CP), are complex. A single case study indicates successful treatment with this new orthosis (MOWA). From the authors’ perspective, this innovative fitting concept is promising and will contribute to creating more efficient care within a multidisciplinary team.

Due to their lightweight potential, the use of fiber-reinforced polymers is the current standard for many technical fields of application. Especially, the automotive and aerospace sectors are to be emphasized. This entails a sophisticated knowledge regarding the material properties, since the safety standards applied in these fields are of high importance. To ensure the safety of the components, a detailed mechanical material characterization is indispensable. The aim of this work was to investigate different influencing factors on the fatigue behavior of carbon fiber-reinforced polyurethane, which is to be certified for aviation applications. Tensile tests provided a basic understanding of the material properties, which appeared to be affected by the specimen width, varied from 3 to 25 mm, by up to 30%. Subsequently, the influence of the cutting direction was investigated in the course of the fatigue tests. Thus, the fatigue strength of longitudinally cut specimens was found to be higher than that of transversely cut specimens by 6%. By means of specific measurement technologies, the material responses were associated with crack initiation and propagation during the fatigue lifetime. The material properties, such as the thermoelastic effect, could be examined during the fatigue tests. Furthermore, turning points in the courses of the characteristic values of the material and correlations with local phenomena were identified.