Additive manufacturing techniques for orthotics

Abstract

An orthotic device for a patient's foot includes a shell that is configured to structurally support the patient's foot. The shell has a variable thickness along a dimension of the shell. The shell is configured to undergo flexion throughout the shell. The variable thickness of the shell targets areas of increased stress.

What is claimed is: 
     
         1 . An orthotic device for a patient's foot, the orthotic device comprising:
 a shell configured to structurally support the patient's foot, the shell having a variable thickness along a dimension of the shell;   wherein the shell is configured to undergo flexion throughout the shell;   wherein the variable thickness of the shell targets areas of increased stress.   
     
     
         2 . The orthotic device of  claim 1 , wherein the orthotic device is a shoe insert configured to be worn on the patient's foot. 
     
     
         3 . The orthotic device of  claim 1 , wherein the shell is configured to completely contain a heel of the patient's foot. 
     
     
         4 . The orthotic device of  claim 1 , wherein the shell is configured to provide medial support for the patient's foot. 
     
     
         5 . The orthotic device of  claim 1 , wherein the shell is configured to provide lateral support for the patient's foot. 
     
     
         6 . The orthotic device of  claim 1 , wherein the shell is configured to undergo deformation without sustaining structural damage. 
     
     
         7 . The orthotic device of  claim 1 , wherein a thickness of the shell at a first longitudinal position of the shell is different than a thickness of the shell at a second longitudinal position of the shell. 
     
     
         8 . The orthotic device of  claim 1 , wherein the variable thickness is configured to accommodate for differences in an anatomical structure of the patient's foot. 
     
     
         9 . The orthotic device of  claim 1 , wherein the orthotic device is configured for use with a patient having valgus of the patient's foot, the shell configured to provide gradual offset to an anatomy of the patient's foot. 
     
     
         10 . The orthotic device of  claim 1 , wherein the orthotic device is configured for use with a patient having varus of the patient's foot, the shell configured to provide gradual offset to an anatomy of the patient's foot. 
     
     
         11 . The orthotic device of  claim 1 , wherein a geometric shape and the variable thickness of the shell are configured to account for unique anatomical structure of the patient's foot to relieve stress along edges, sides, and a bottom of the patient's foot. 
     
     
         12 . A method for manufacturing an orthotic device for a patient's foot, the method comprising:
 using a digital scanner to capture an anatomical structure of the patient's foot and generate a patient scan file;   modifying the patient scan file into a device shape;   creating a printer-compatible file for an additive manufacturing device; and   additively manufacturing the printer-compatible file using the additive manufacturing device to generate the orthotic device.   
     
     
         13 . The method of  claim 12 , wherein the device shape is a schematic of the orthotic device. 
     
     
         14 . The method of  claim 13 , further comprising:
 converting the schematic of the orthotic device that captures the anatomical structure of the patient's foot to a computer assisted design (CAD) file or a computer assisted manufacturing (CAM) file.   
     
     
         15 . The method of  claim 12 , wherein modifying the patient scan file comprises:
 using at least one of a buildup technique or a reduction technique to generate the printer-compatible file so that the printer-compatible file accommodates the anatomical structure of the patient's foot.   
     
     
         16 . The method of  claim 12 , wherein additively manufacturing the printer-compatible file comprises:
 providing layers of material on top of each other in succession to produce the orthotic device.   
     
     
         17 . An orthotic device for a patient's foot manufactured using additive manufacturing, the orthotic device comprising:
 a shell configured to structurally support the patient's foot, the shell having a variable thickness along a dimension of the shell;   wherein the variable thickness of the shell increases at areas of increased stress.   
     
     
         18 . The orthotic device of  claim 17 , wherein the shell is configured to undergo flexion throughout the shell. 
     
     
         19 . The orthotic device of  claim 17 , wherein the orthotic device is configured for use with a patient having valgus of the patient's foot, the shell configured to provide gradual offset to an anatomy of the patient's foot. 
     
     
         20 . The orthotic device of  claim 17 , wherein the orthotic device is configured for use with a patient having varus of the patient's foot, the shell configured to provide gradual offset to an anatomy of the patient's foot.