Optimizing children's hand orthosis design: A study on contact pressure distribution using FSR sensors
Year: 2025
Type: article
Abstract: The design and comfort of hand orthoses for children are crucial for effective therapeutic outcomes. This research primarily aims to measure the contact force between the hand and orthoses in children under 10 years old and use this data as a loading condition for topology optimization to reduce high-pressure areas, thereby enhancing wear comfort. Force Sensing Resistor (FSR) sensors were employed to record the contact force at 16 specific points on the orthoses using a voltage divider circuit with two different setups: the Teensy 3.5 chip board for 12-bit precision and the Elegoo Mega 2560 chip board for 10-bit precision. These force measurements were compared to existing data from an adult to highlight differences in pressure distribution. Additionally, the study demonstrates the feasibility of integrating precise sensor data into computational models for optimizing medical device designs. While this data could also be utilized in future research for sizing adjustments to optimize the soft padding materials within the orthoses for improved comfort, this aspect is not the primary focus of the current study. The results underscore the importance of developing orthotic designs tailored to pediatric users, informed by precise contact force measurements, to mitigate critical pressure sores and improve overall comfort. • This study presents a novel framework integrating topology optimization (TO) with additive manufacturing (AM) to develop patient-specific hand orthoses, minimizing material use while maintaining performance. Through TO, material usage is reduced by over 50%, achieving a lightweight design that preserves stiffness and stability. The customized orthoses, based on patient scans, show a 10–15% reduction in contact pressure, improving comfort and fit. Biomechanical principles were applied to optimize load-path engineering, particularly for pediatric needs, while utilizing FSR sensors to measure patient-specific contact pressure, thereby reducing pressure sores and further enhancing design adaptability. A comparative evaluation of three design variants identified an optimal balance between stiffness, manufacturability, and load distribution, featuring a truss structure that reduces stress concentration. This approach offers significant potential for advancing clinical applications in musculoskeletal rehabilitation, enhancing durability, adaptability, and patient-centered design in medical orthotics. 1. Integration of Topology Optimization and Additive Manufacturing : This study introduces a novel framework combining topology optimization (TO) with additive manufacturing (AM) to develop patient-specific hand orthoses that reduce material use without sacrificing performance. 2. Enhanced Material Efficiency and Structural Integrity : Through TO, redundant material is minimized by over 50%, resulting in a lightweight, structurally effective orthosis. The optimized design-maintained stiffness and stability while reducing the overall material volume. 3. Customized Fit and Improved Comfort : The optimized orthosis, designed based on patient-specific scans, achieved a 10–15% reduction in contact pressure at critical points, enhancing comfort and fitting adaptively to individual hand anatomy. 4. Comparative Evaluation of Three Design Variants : Among the three designs evaluated, one of the design variants demonstrated the best balance between stiffness, manufacturability, and load distribution. This design featured a robust truss structure that reduced stress concentration while maintaining structural adaptability and flexibility. 5. Biomechanically Driven Design for Pediatric Applications : Incorporating biomechanical principles, the study addressed unique pediatric requirements, offering targeted load-path engineering to support growth and improve patient care outcomes. 6. Potential Impact on Clinical Practice : This research highlights the significant advantages of topology-optimized orthoses in musculoskeletal rehabilitation, paving the way for improved durability, adaptability, and patient-centered design in medical orthotics.
Source: Materials & Design
Language: English
Subfield: Biomedical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $3,650
Awards: G2755649450, G5295181574
OpenAlex ID: W4407134266