Design and Additive Manufacturing of Customized Orthotic Parts Using Innovative Bio-Composite Thermoplastic Filaments

In recent years, additive manufacturing has been expanding rapidly in several sectors, including marine, aerospace and civil, offering broad design freedom and environmental/ecological advantages for the production of fully functional products. Particularly in the biomedical area, interesting manufacturing methods have recently been developed for the customisation of orthotic devices by automating the acquisition process and 3D printing. Today, in the development of complex geometries, it is necessary to meet certain design specifications, such as mechanical strength, surface finish, light weight, breathability and aesthetic appearance, which can potentially be met by manufacturing with 3D printers. This research deals with the development and implementation of organic bioplastic compounds based on polylactic acid (PLA) and organic by-products for additive manufacturing applications of customised orthotic parts. PLA, filled with reinforcements and additives, can be used to produce durable and functional parts for improved structural performance. By studying specific orthotic cases with CAD-CAE techniques, its potential mechanical properties will be evaluated and compared to highlight its performance comparable or even superior to that of classical PLA. The proposed methodology reduces production costs and environmental impact. Thanks to the presence of reinforcements and additives, the new organic bioplastic compounds are more biodegradable, while improving some of the functionality and comfort requirements of customised orthoses.