Development of Novel 3d-Printed Knee-Ankle-Foot Orthosis for Clubfoot Treatment and Clinical Application

Clubfoot is the most common congenital foot disorder, with an incidence of 1 to 2 per 1,000 live births. Treatment can achieve a painless and functional limb, but the tissues remain abnormal. The Ponseti method, described as a series of casts (plaster of Paris) placed weekly to sequentially correct each deformity of the newborn foot, is used worldwide to treat clubfoot. In most patients, casting is followed by percutaneous lengthening of the Achilles tendon to correct equinus. Then, full-time brace wear commences for 3 months, followed by brace wear during sleep to maintain correction until the child reaches school age. However, the technique of Ponseti method is not familiar to physicians other than pediatric orthopedic surgeons. We try to use 3D-printed knee-ankle-foot orthoses to simulate the Ponseti techniques to correct the clubfoot deformity. Both patients and physicians can benefit from this innovation. The clubfoot deformity is characterized by midfoot cavus, forefoot adductus, and hindfoot varus and equinus. Each deformity is rigid to a varying degree and need to be corrected. First, we used a clubfoot training model to practice 3D scanning techniques. Second, we designed a 3D-printed knee-ankle-foot orthosis to cover the training mode. Third, we used a 3D computer simulation program to simulate the Ponseti method. Fourth, we designed 5 serial 3D-printed knee-ankle-foot orthoses to simulate the Ponseti serial casting technique. Finally, we applied the 3D-printed orthoses to patients weekly. The Achilles tendon tenotomy will be performed before the 5th 3D-printed cast. Clubfoot is a common congenital foot disorder. Ponseti method has gained wide acceptance to treat clubfoot deformity. However, the Ponseti method is not familiar to physicians other than pediatric orthopedic surgeon. We believe that the novel 3D-printed knee-ankle-foot orthoses can provide a lot of help. Doctors around the world can utilize 3D printing technique to create the orthoses for their patients.

Project ID:PC10907-0867
External Project ID:MOST109-2314-B182-023