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. 2020 Apr 27;10:7028. doi: 10.1038/s41598-020-63937-1

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© The Author(s) 2020

Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made. The images or other third party material in this article are included in the article’s Creative Commons license, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons license and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/.

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Schematic representation of design workflow and fabrication process of custom orthosis. (a) A 3D scan of the patient is acquired using Artec EVA scanner³²; (b) the user positions simple geometry over the region of interest, with feedback on how geometry placement relates to the 3D scan; (c) This geometry is fitted then relaxed away from the 3D scan surface to improve patient comfort; (d) Deformation energy is mapped to the surface (red = highest deformation energy; blue = lowest deformation energy); (e) Deformation energy is used to generate a porous pattern, this porous surface is extruded to form 3D printable geometry. Steps (c-e) are automated and require no user input. (f) The orthosis is 3D printed using Stratasys Fortus 380mc³². (g) A variational surface cutting algorithm³³ is used on the geometry from (c) to create a template for cutting orthosis padding. (h) The assembly of the printed component and padding results in the final cervical orthosis. The workflow can be repeated and iterated based on feedback from the patient and clinical team. Photos: David Bishop and Matthew Town.