Design Process

General Design Process

• Basical CAD model training
• First prototype (low resolution)
• Meeting with mentor, Dr. Matt Caster
• Research new functions and terms for motor movement
• Tech Shop Classes (http://www.techshop.ws)
• Vacuum Former
• Carbon Fiber Basics
• MeshMixer training
• Create second prototype and adjust CAD model if necessary
• Meet with expert manufacturer (ex. Donny) to go over how to fabricate model and Dr. Matt Caster again to go over the design itself.
• Continue fabricating more prototypes, with different materials, and then testing each one (making adjustments as necessary) --> higher resolution

Abstract(General Synopsis/Design of Project):

• General Topic:
• Many people suffer from decreased mobility, and a common issue associated with this is drop-foot. Drop-foot occurs when individuals do not have the strength to lift up their toes while walking. This means that in the process of walking, the toes will not be lifted up in time to bring the foot through, and the individual has a greater chance of falling. Often, however, these people cannot take the risk of falling, so they decide to use such devices as canes or walkers to support their body weight while walking.  This use of a walker doesn’t fix their walking capabilities, in this case Drop Foot, but allows for facilitated movement to and from places.  A walker’s weight and size definitely discourage many people from using it.  Though, with our device, we offer an alternative to these people that deliberately promotes natural motor movement in the foot without an assistive device that merely hides the ailment.  
• Specific Question:
• We have designed a foot brace to encourage these people who suffer from decreased mobility to walk correctly, lifting up the toes and pushing off (plantar and dorsiflexion) as much as the individual requires. The product will also be mostly 3D printed, so it will decrease the costs for the consumer.  
• Method:
• We are using an AFO that we saw at Union Orthotics as our guide, and after meeting with physical therapist Dr. Matt Caster, we began designing our own. We used AutoDesk Inventor to create the calf-section and have experimented with different ways to construct the sole. These methods include using the scanner, the vacuum former at TechShop, Inventor, and Meshmixer.  Through these methods, we have begun prototyping the device to reach its optimal potential.
• Further Work (as of January 4, 2016) :
• We are still trying to figure out how to effectively and efficiently construct the sole to fit in the client’s shoe as well as a way to connect the two sections. After we complete the general form for the brace, we will begin designing the elasticity function which will allow the user to customize the amount of assistance he/she needs to execute the correct gait motion - allowing the user to regain normal balance and function of their foot while walking.  

March 3, 2016 Poster to accompany presentation at Tech Shop on March 8th