With emerging scanning and printing technologies, individually customized rehabilitation devices have become much easier to produce. We hope to create a finger or full hand rehabilitation system using an elastic polymer that is customized to an individual’s geometric properties.
Project Goals:
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Create an individually customized functional rehabilitation device using mass customization
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Use topology optimization for cheap and quick production
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Create a comfortable and useful product
Steps to Success:
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Determine a way to model the finger/ hand. We hope to do this by using a phone, table top scanner, or CT scanner. If this proves to be too difficult we may have to measure geometric properties by hand and create a CAD model from that.
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Using this finger or hand model, a CAD model can be created in solidworks of a device that surrounds the fingers. We hope to create a model that closely follows the contour of the finger and fits snuggly.
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Topology optimization software will be used to reduce material and allow for a faster print while maintaining mechanical properties. This will allow the device to be more breathable and as a result more comfortable for the user. This will be done using topOpt, the software shown in class.
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We must create a product that effectively restricts motion to allow for rehabilitation. To achieve this we must use appropriate materials to create resistance while still flexible. A possible combination of soft and stiff materials will be used to arrive at the desired result.
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Printing and testing will be done with the user that the product was designed for. Parameters such as comfort, durability, and resistance to motion can be measured to evaluate the success of our design.
Difficulties:
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Scanning:
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Phone scanner was unsuccessful, after taking multiple pictures the software was unable to compile them into a solid part. The resulting model had holes and overall very poor resolution
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Scanner in lab doesn’t work with door open which is necessary to scan your hand
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Micro-CT scanner must also be closed to run
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Design:
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We looked at whether we wanted to design a rehabilitation device or simply a cast type device that would keep the finger/hand rigid. We decided to go with a rehabilitation device because it posed a more complex design challenge that would utilize several additive manufacturing concepts.
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There are many current rehabilitation devices so we have to decide on one and focus on a specific design
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Figure 1. Initial sketch of rehabilitation design
Figure 2: Current Product Design
Figure 3 – Design Ideas