A Computational Model of Custom 3D Printed Hand Orthosis

3D printed patient-specific hand orthoses can improve the efficiency of the treatment and the comfort of the patient, but since each customized orthosis is a virtually unique device, it is difficult to assess their mechanical response in the design phase, both experimentally and numerically. The Finite Element Method (FEM) could be used to predict the deformation of the orthosis under predetermined loads, but patient-specific models including interaction with the hand are still lacking. In the present work we present a computational model in which, starting from the scan data of the hand used to manufacture the orthosis, a FEM model of the hand is generated, including a skeletal structure. Hand bones positions and dimensions can be defined basing on simple anatomical measurements or literature data and the stiffness of the joints can be tuned in relation to patient pathology. The remaining hand volume consists of a soft tissue region, mimicking the non-linear mechanical behaviour of skin and muscles. Results show that both functional and structural indexes can be analyzed, such as contact pressures, stress state or the compliance of the orthosis, providing useful information for the design of custom devices. By using mesh deformation algorithms, the scan data could be used to generate different orthosis designs in target positions defined by the therapist and, taking advantage of a parametric model under development, the skeletal structure could be adapted correspondingly, providing an innovative pathway to investigate the response of the orthosis during the whole rehabilitation.