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<p>Ankle–foot orthoses (AFOs) are widely used assistive devices that improve gait and stability in patients with lower limb disorders. However, conventional manufacturing methods are often time-consuming and offer limited flexibility for patient-specific designs. This study investigates the optimisation of fused deposition modelling (FDM) process parameters to enhance the mechanical performance and surface quality of polylactic acid carbon fibre (PLA-CF) for orthotic applications. A Taguchi L9 experimental design was applied to evaluate the effects of layer thickness (0.1–0.3&#xa0;mm), nozzle temperature (200–220&#xa0;°C), printing speed (30–90&#xa0;mm/s), and raster orientation (0°, ± 45°, 90°). The optimal parameter combination consisted of a 0.2&#xa0;mm layer thickness, 210&#xa0;°C nozzle temperature, 60&#xa0;mm/s printing speed, and ± 45° raster orientation, experimentally achieving a maximum compressive strength of 81 ± 1&#xa0;MPa and a minimum surface roughness of 7.43&#xa0;μm. Differential scanning calorimetry (DSC) revealed that crystallinity increased from 1.59% in the as-printed condition to 30.41% after annealing. Among the annealing conditions investigated, treatment at 100&#xa0;°C for 2&#xa0;h achieved the highest compressive strength of 91 ± 1&#xa0;MPa. Finite element analysis (FEA) of AFO models with thicknesses of 4, 6, 8, and 10&#xa0;mm identified the 8&#xa0;mm design as the optimal configuration, providing the best balance between weight, cost, and mechanical performance, with a maximum stress of 11.39&#xa0;MPa, deformation of 8.9&#xa0;mm, and a safety factor of 3.68. These findings demonstrate that FDM optimisation can significantly improve PLA-CF orthoses, providing a cost-effective and customisable framework for personalised orthopaedic applications.</p>

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Mechanical performance optimisation of 3D printed PLA carbon fibre for ankle foot orthosis applications

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月9日

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  • Nejmeddine Layeb,
  • Adrian Ionuț Cadiș,
  • Istvan Oldal,
  • László Zsidai

摘要

Ankle–foot orthoses (AFOs) are widely used assistive devices that improve gait and stability in patients with lower limb disorders. However, conventional manufacturing methods are often time-consuming and offer limited flexibility for patient-specific designs. This study investigates the optimisation of fused deposition modelling (FDM) process parameters to enhance the mechanical performance and surface quality of polylactic acid carbon fibre (PLA-CF) for orthotic applications. A Taguchi L9 experimental design was applied to evaluate the effects of layer thickness (0.1–0.3 mm), nozzle temperature (200–220 °C), printing speed (30–90 mm/s), and raster orientation (0°, ± 45°, 90°). The optimal parameter combination consisted of a 0.2 mm layer thickness, 210 °C nozzle temperature, 60 mm/s printing speed, and ± 45° raster orientation, experimentally achieving a maximum compressive strength of 81 ± 1 MPa and a minimum surface roughness of 7.43 μm. Differential scanning calorimetry (DSC) revealed that crystallinity increased from 1.59% in the as-printed condition to 30.41% after annealing. Among the annealing conditions investigated, treatment at 100 °C for 2 h achieved the highest compressive strength of 91 ± 1 MPa. Finite element analysis (FEA) of AFO models with thicknesses of 4, 6, 8, and 10 mm identified the 8 mm design as the optimal configuration, providing the best balance between weight, cost, and mechanical performance, with a maximum stress of 11.39 MPa, deformation of 8.9 mm, and a safety factor of 3.68. These findings demonstrate that FDM optimisation can significantly improve PLA-CF orthoses, providing a cost-effective and customisable framework for personalised orthopaedic applications.