Design of a Customized Neck Orthosis for FDM Manufacturing with a New Sustainable Bio-composite

The interest in developing customized external orthopaedic devices, thanks to the advent of Additive Manufacturing (AM), has grown in recent years. Greater attention was focused on upper limb casts, while applications to other body’s parts, such as the neck, were less investigated. In this paper the computer aided design (CAD) modelling, assessment and 3D printing with fused deposition modelling (FDM) of a customized neck orthosis are reported. The modelling, based on anatomic data of a volunteer subject, was aimed to obtain a lightweight, ventilated, hygienic and comfortable orthosis compared to the produced medical devices generally used for neck injuries. CAD models with different geometrical patterns, introduced for lightening and improving breathability, were considered, specifically, a honeycomb pattern and an elliptical holes pattern. These models were structurally assessed by means of finite elements analysis (FEA). Furthermore, an innovative composite material was considered for 3D printing. The material, Hemp Bio-Plastic® (HBP), composed by polylactic acid (PLA) and hemp shives, offers different advantages including lightweight, improved superficial finish and antibacterial properties. The results obtained in terms of design methodology and manufacturing by 3D printing of a prototype have shown the feasibility to develop customized cervical orthoses, with potentially improved performance with respect to cervical collars available on the market also thanks to the use of the innovative composite material.