How to make your 3D printed AFO - Forma Workflow

Here is a step-by-step tutorial for using the "Forma" workflow.

After selecting your model, choose the "Custom" workflow. This option allows you to customize the scan correction, design, and printing of your AFO.

You can also choose whether to include holes for laces in the TPU inlay, and whether the TPU inlay should be attached to the AFO.

If you have selected a dynamic model (B8), you can now choose the articulation type and specify the desired degree of mobility for the device.

Now it’s time to enter the patient details, such as the patient’s weight (kg) and height (cm). In addition, we also ask for the patient’s clinical profile. Here, you can choose from several options.

The activity level is also very important. Please select it as accurately as possible, so our designers understand how the AFO will be used.

Select whether you want the AFO to be printed by Spentys or if you prefer to print it locally. Then, choose the appropriate material.

Choose a color, if any.
Note: Black AFOs have different size restrictions compared to colored AFOs.

Choose a drawing to be added to the splint. The drawing will be centered on the top of the calf. If you don’t want a drawing, you can also choose to add your logo to the splint instead.

Add your scan to the order.
There are three options available: Limb, Mold, or Cast.

• For the Limb option, you only need to upload the scan.

• For the Mold option, it is important to place physical landmarks on the mold.

• For the Cast option, in addition to placing physical landmarks on the mold, you must also provide the thickness of the cast as well as some accurate measurements of the limb.

Please place a thumbtack/pushpin on the following anatomical points:

Below is an overview of the measurements we need for the Cast option:

During the "correct" step, select Forma correction to access the 3D software.

You will then have to follow the app to complete the following: 

• Clean up
• Pose
• Sculpt

To proceed with the "clean up" of the scan, the application will ask you to select the object in the 3D scene you want to use and then place two reference points that the software will use to reorient the scan.

Place these points correctly because they will be crucial for the rest of the modifications.

The first point is located in the center of the medial malleolus. The second is on the anterior aspect of the tibia, halfway up the bone.

After that, you will be able to move a virtual square on the scan that will delimit the cut of your scan.

The next step is the rectification step.

It will first ask you to place a series of points on the ankle joint so that the software understands or deforms the foot correctly.

Once all these points are validated, the application will give you access to sliders at the bottom of the screen. Once you click one of the buttons, the slider will activate and allow you to modify the foot in degree.

If you have already experimented with the FreeForma tool, the sculpting tool works similarly: it will draw your loads/unloads directly on your model.

 The application offers you tools to gain precision. Here is a presentation of the tools at the bottom of the screen from left to right:

• The arrows allow you to go back/forward in your strokes.
• The push/pull switch will allow you to switch between charge and discharge modes.
• The brush tool to applies depth changes to the scan while the eraser tool removes those changes on that area. 
• The flatten tool: push all the volumes on the same height.
• The levelling tool: make an average between two volumes
• The slider "brush radius" will allow you to define the diameter of your brush during your drawings.
• Finally, the slider "limit value" will help you precisely define the height of your deformations.

Then fill in the final height (cm) and the final length (cm) of the AFO.

Please specify your preference regarding the offset that should be provided (for example for foam addition). Also let us know whether you would like a small hole pattern, or if the AFO should be closed (in which case no hole pattern will be included).

You now have three options for the AFO design:

• Standard Design: Use Spentys' standard design.

• Custom Design: Spentys designers will create the device based on your custom inputs.

• Sketch Design: Design your AFO using our interactive tool.

Below you’ll find a video about the last option:

Next up, you will be able to customize the thicknesses of your AFO. Two options here: 'Standard' or 'Extra Rigid.'

Then you will be asked to choose your closing system among the emplacement of the drawings.

 

Last but not least!
Please provide the shipping address and invoice address.

You will also have the option to indicate whether you would like a model review. Visualise the 3D model of the product before it gets printed. Please note: this may affect the delivery time.

Congratulations! You managed to create your first customized AFO!