Orthoses are orthopedic devices that provide support to certain parts of the body, facilitating or limiting movement. They are usually used in the treatment process after injuries, surgeries or chronic illnesses. Although the production stages of orthoses vary depending on the materials used, whether they are personalized or not and the treatment purposes, the basic steps are generally similar.
Production Stages of Orthoses:
1. Patient Assessment and Needs Analysis
Medical Assessment: The first stage of orthosis production begins with patient assessment. The orthopedist or physiotherapist examines the patient's anatomical structure, medical history and needs. It is determined which area needs to be supported and what kind of movement restriction or support is required.
Determining Treatment Goals: The design process is planned in accordance with the purpose for which the orthosis will be used (support, protection, rehabilitation). For example, a knee orthosis can provide stabilization after an injury, while a spinal orthosis can correct posture disorders.
2. Measurement and Mold Making
Patient-Specific Measurements: Especially in custom orthoses, detailed measurements are taken from the area of the body to be supported. These measurements can be made manually or with three-dimensional scanning devices. This stage is critical for the orthosis to fully adapt to the body.
Plastic Mold: In some cases, especially in more complex or custom orthoses, a plaster mold is taken from the relevant part of the body and production begins. The plaster mold ensures that the orthosis is exactly compatible with the body form.
Digital Mold and 3D Scanning: Today, with more modern methods, a digital mold can be created with the help of 3D scanners. This technology replaces traditional methods such as plaster mold making and offers faster and more precise results.
3. Design and Prototype Preparation
Computer-Aided Design (CAD): After the mold and measurements are taken, the design process of the orthosis begins. Using computer-aided design (CAD) software, the compatibility and functionality of the orthosis with the body are calculated. In this process, points that will support or restrict movement are determined.
Material Selection: The material to be used in the orthosis is an important part of the design and purpose of use. Various materials such as carbon fiber, thermoplastic, metal, foam or leather are preferred in terms of the lightness, durability and flexibility of the orthosis.
Prototype Production: The orthosis designed for personalized or complex orthopedic devices is first produced as a prototype. The prototype is used to test the suitability of the measurements and design.
4. Production
Thermoforming: Thermoforming, a widely used technique in orthosis production, is used to shape the orthosis from plastic or composite material. During this process, the material is heated and softened, then placed in the mold and cooled.
Assembly of Joints and Metal Parts: In orthotic devices that require movable joints or metal supports, these parts are assembled. The hinges, screws and other mechanical parts in the orthosis are carefully placed.
3D Printing (Additive Manufacturing): 3D printing technology has gained popularity in recent years in the production of personalized orthosis. With this method, the designed orthosis is produced directly from the 3D printer. This allows complex and detailed orthosis to be produced quickly and precisely.
5. Surface Treatment and Final Touches
Surface Smoothing: After the production phase is completed, the surface of the orthosis is smoothed with fine workmanship. This process is done to prevent discomfort or irritation on the skin during use of the material. Sharp edges are removed and the surface is smoothed.
Coating and Support Elements: Some orthosis are made more comfortable by covering them with leather or foam coatings. In addition, additional support elements such as straps, buckles or velcro bands are added.
6. Trial and Application
Patient Fit Test: The produced orthosis is tried on the patient. At this stage, the orthosis's fit with the body, comfort and functionality are tested. Small adjustments can be made if necessary.
Function Tests: The orthosis is checked to see if it supports the patient's movements and whether it stands in the correct position. It is also important that the device can be worn comfortably throughout the duration of use.
7. Education and Instructions for Use
Patient Education: The patient is trained on how to put on, take off and maintain the orthosis. Correct usage instructions are vital, especially for orthosis that require long-term use.
Control and Follow-up: Especially for custom orthoses, the patient is checked at regular intervals. It is observed whether the orthosis has deformed over time or whether the patient experiences discomfort during use.
You can visit our website www.canerdem.com.tr for the types of prosthesis and orthosis you need.