Abstract
Orthoses are provided and methods for making orthoses. The orthosis is formed by providing a 3D printer, loading the 3D printer with a fabric layer, and loading a 3D printing material into the 3D printer. A 3D printing operation is performed wherein at least one 3D printed layer is 3D printed directly on the fabric layer. The fabric layer imprinted with the 3D printed layer is removed from the 3D printer.
Claims
1. A method for producing an orthosis, the method comprising: providing a 3D printer loaded with a 3D printing material; loading a fabric layer into the 3D printer; performing at least one 3D printing operation to form at least one 3D printed layer directly on the fabric layer; removing, from the 3D printer, the fabric layer imprinted with the 3D printed layer; and forming the fabric layer imprinted with the 3D printed layer into a glove for use as an aid in manufacturing technology.
2. The method according to claim 1, wherein the loading of the fabric layer into the 3D printer takes place after a first 3D printing operation is performed and before a second 3D printing operation is performed in the 3D printer.
3. The method according to claim 1, wherein, after and/or before removing, from the 3D printer, the fabric layer imprinted with the 3D printed layer, cutting the fabric layer along a contour.
4. The method according to claim 1, wherein when performing the 3D printing operation and when forming the 3D printed layer in the 3D printer directly on the fabric layer, an electronic component is formed in the 3D printed layer.
5. The method according to claim 1, wherein when performing the 3D printing operation and when forming the 3D printed layer in the 3D printer directly on the fabric layer, forming a metamaterial in the 3D printed layer.
6. The method according to claim 1, wherein when performing the 3D printing operation and when forming the 3D printed layer in the 3D printer directly on the fabric layer, 3D printing a plurality of individual printed layer elements.
7. The method according to claim 6, wherein the plurality of individual printed layer elements inhibit the degrees of freedom of movement of a user.
8. A method for producing an orthosis, the method comprising: providing a 3D printer loaded with a 3D printing material; loading a fabric layer into the 3D printer; performing at least one 3D printing operation to form at least one 3D printed layer directly on the fabric layer; and removing, from the 3D printer, the fabric layer imprinted with the 3D printed layer, wherein the at least one 3D printed layer comprises an electronic component.
9. The method according to claim 8, wherein the loading of the fabric layer into the 3D printer takes place after a first 3D printing operation is performed and before a second 3D printing operation is performed in the 3D printer.
10. The method according to claim 8, wherein, after and/or before removing, from the 3D printer, the fabric layer imprinted with the 3D printed layer, cutting the fabric layer along a contour.
11. The method according to claim 8, wherein when performing the 3D printing operation and when forming the 3D printed layer in the 3D printer directly on the fabric layer, forming a metamaterial in the 3D printed layer.
12. The method according to claim 8, wherein when performing the 3D printing operation and when forming the 3D printed layer in the 3D printer directly on the fabric layer, 3D printing a plurality of individual printed layer elements.
13. The method according to claim 12, wherein the plurality of individual printed layer elements inhibit the degrees of freedom of movement of a user.
14. A glove orthosis comprising: a fabric layer; and a 3D printed layer formed over at least a portion of the fabric layer, wherein the 3D printed layer comprises an electronic component.
15. The glove orthosis according to claim 14, wherein the 3D printed layer is divisible into at least two regions, wherein a first region is flexible and/or bendable, and a second region is stiffened and/or strengthened relative to the first region.
16. The orthosis glove according to claim 14, wherein the 3D printed layer has a plurality of printed layer elements, wherein spaces are formed between the printed layer elements, such that the printed layer elements are movable relative to one another.
17. The orthosis glove according to claim 16, wherein the printed layer element of the 3D printed layer of the orthosis has a longitudinal axis, a connection element connecting the printed layer element to the fabric layer, and a surface element exposed to an environment of the orthosis, wherein the printed layer element extends from the connection element to the surface element along the longitudinal axis.
18. The glove orthosis according to claim 16, wherein the printed layer elements are elongated.
19. The glove orthosis according to claim 14, wherein the 3D printed layer comprises a metamaterial structure, wherein the metamaterial structure, under the effect of a tensile force in a first direction (y direction), expands in a second direction (x direction).
20. The glove orthosis according to claim 14, wherein the electronic component is an integrated electronic component comprising a communications or computing device for transmitting, receiving, processing and/or storing data.
Description
DRAWINGS
[0040] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
[0041] FIGS. 1a and 1b each show a perspective view of examples of orthoses from the prior art;
[0042] FIG. 2 shows a schematic view of the layout of an orthosis according to the present disclosure;
[0043] FIGS. 3a-3b show a schematic view of an example of a design or arrangement of a 3D printed layer according to the present disclosure;
[0044] FIG. 4 shows a schematic view of a first alternative design or arrangement of a 3D printed layer according to the present disclosure;
[0045] FIGS. 5a-5b show a schematic view of a second alternative design or arrangement of a 3D printed layer according to the present disclosure;
[0046] FIG. 6 shows an example of an orthosis according to the present disclosure in a perspective view;
[0047] FIG. 7 shows an illustration of an example of a production method according to the present disclosure; and
[0048] FIG. 8 shows a flow chart of an example of a production method according to the present disclosure.
[0049] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
DETAILED DESCRIPTION
[0050] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
[0051] FIG. 1a shows an orthosis 10, designed as a thumb orthosis, from the prior art. The orthosis 10 is integrated in a glove 11. The thumb orthosis protects the thumb joints of the user 19, for example in assembly operations that are performed very frequently and that use a pressing-in movement of the thumb. This lessens the strain on the joints of the thumb. FIG. 1b shows an orthosis 10 from the prior art, designed as an exoskeleton 12 for the forearm and the palm. Such an orthosis 10 can also be used for medical purposes, and also as an aid that assists frequently performed movements, in particular in assembly operations, for example during serial manufacture on an assembly line in the automotive industry.
[0052] FIG. 2 shows a basic layout of the layers of an example of an orthosis 10 according to the present disclosure (cf. FIG. 6). A first layer or fabric layer 2 is provided which, during use of the orthosis 10, forms the contact with the skin of the user 19 (cf. FIG. 6) and thus also permits a comfortable feel when intensive effort causes sweating. A second layer or 3D printed layer 4 is applied onto the fabric layer 2. The 3D printed layer 4 has a multiplicity of printed layer elements 13, wherein the printed layer elements 13 are designed as a multiplicity of elongate components, i.e., pin-shaped or peg-shaped components. A printed layer element 13 has at least one surface element 14, for example for forming a contact with other objects, and a connection element 15 for connecting the printed layer element 13 to the fabric layer 2. Through the geometric formation of the printed layer elements 13, certain movements with the orthosis 10 by the user 19 (cf. FIG. 6) can be made more difficult or easier, depending on the requirements. By means of the surface elements 14 being arranged flush on one another, lateral movements of the printed layer elements 13 relative to one another can be made difficult. By means of a tapering, i.e., a reduction of a cross section starting from the surface element 14 as far as the connection element 15, spaces 16 form inside the 3D printed layer 4, which spaces 16 permit a desired freedom of movement of the user 19 (cf. FIG. 6). In other words, the fabric layer 2 may be directed toward the user (cf. FIG. 6), while the 3D printed layer 4, in particular the surface elements 14 thereof, is directed toward the environment 25 of the orthosis 10 and forms the outer side 27 of the orthosis 10. As can be seen from FIG. 2, by way of example, the surface elements 14 can be polygonal (e.g., hexagonal), and in a form is shaped like a honeycomb. The 3D printed layer 4 can be flexible and/or bendable, stiffened and/or strengthened, or a combination thereof (e.g., the 3D printed layer may be divisible into regions, and a first region may be flexible and/or bendable, and a second region may be stiffened and/or strengthened relative to the first region).
[0053] FIG. 3a shows a specific regional arrangement of a 3D printed layer 4 on the fabric layer 2. Alternatively, the 3D printed layer 4 can also be applied to the fabric layer 2 over the whole surface. To produce the orthosis 10 (cf. FIG. 6), a contour 5 can be applied to the fabric layer 2. The fabric layer 2 can be cut out along the contour 5. By subsequent cutting out of the fabric layer 2 after the application of the 3D printed layer 4 along the final contour 5, fraying of the fabric layer 2 that has taken place during the production method can be eliminated. FIG. 3b shows a further specific regional arrangement of a 3D printed layer 4 on a fabric layer 2, wherein the 3D printed layer 4 is formed at least partially with a metamaterial 6. Such a metamaterial 6, for example during an expansion of the 3D printed layer 4 in a y direction, can also bring about a lengthening of the fabric layer 2 in an x direction.
[0054] FIG. 4 shows a further possible variation of an arrangement of a 3D printed layer 4 on a fabric layer 2 and a possible design of the individual printed layer elements 13. Depending on the design of the individual printed layer elements 13, e.g., as pegs, small rods or pyramids, various degrees of freedom (DOF) of the fabric layer 2 and thus of the orthosis 10 can be realized during use of the orthosis 10. Starting from their surface element 14, the printed layer elements 13 are designed with an unchanging rectangular cross section as far as their connection element 15, for example with respect to the plotted y direction. By virtue of the unchanging cross section and the flush arrangement of the printed layer elements 13, no spaces 16 form between the individual printed layer elements 13 in their starting position, i.e., in their unloaded position. By means of this design there are admissible curvatures 17 of the fabric layer 2, i.e., the fabric layer 2 bulges outward away from the user 19 (cf. FIG. 6), that is to say in the direction of the environment 25 of the orthosis 10. The distance between the surface elements 14 of the individual printed layer elements 13 thus increases, and spaces 16 form between the printed layer elements 13. By contrast, a bulging movement in the opposite direction toward the inner side 26 constitutes an inadmissible curvature 18, wherein the inadmissible curvature 18 of the fabric layer 2 toward the inside, i.e., toward the user 19, is indicated by dashes as an imaginary line 13a. Since no spaces 16 are present between the printed layer elements 13 in their starting position, there is also no freedom of movement for an unwanted or inadmissible curvature 18.
[0055] FIGS. 5a and 5b show a further possible variation of an arrangement of a 3D printed layer 4 on a fabric layer 2, in which, by means of a conical, pyramid-shaped and/or cone-shaped design of the individual printed layer elements 13, a bulging movement of the fabric layer 2 about the z direction is permitted in principle in both directions, i.e., to the inner side 26 and to the outer side 27. Starting from their connection element 15, the printed layer elements 13 taper as far as their surface element 14, for example with respect to the plotted positive y direction. Spaces 16 are thus formed between the printed layer elements 13. During an outward bulging movement of the fabric layer 2 about the z direction, i.e., in the direction of the environment 25 (cf. FIG. 6) of the orthosis 10, the spaces 16 enlarge as a result of the increase in the distance between the individual surface elements 14. During an inward bulging movement of the fabric layer 2 about the z direction, the distance between the individual surface elements 14 decreases, as a result of which the spaces 16 also grow smaller. This bulging movement can be continued until the printed layer elements 13 abut one another or bear flush on one another. The maximum bulging of the fabric layer 2 can be set by the geometric design of the printed layer elements 13. According to FIG. 5b, the printed layer elements 13 can also be designed such that the tapering is formed only with respect to the y direction, and not with respect to the z direction. The teachings illustrated by FIGS. 4 and 5a may be combined with each other. In this way, the individual printed layer elements 13 already lie flush or flat on one another with respect to the z direction, and an inadmissible curvature 18 with respect to the x direction caused by a bulging movement to the inner side 26 is thus suppressed. However, a curvature with respect to the x direction caused by a bulging movement to the outer side 27 in order to form spaces 16 is still possible. In this way, the individual DOF can be different depending on the direction.
[0056] FIG. 6 shows an orthosis 10, designed as a glove 11, on a user 19.
[0057] The orthosis 10 or the glove 11 has an inner side 26 (cf. FIG. 4) directed toward the user 19, and an outer side 27 directed toward the environment 25. To form the glove 11 as a digital glove 11, corresponding applications can already be incorporated in the production by 3D printing. For this purpose, the glove 11 can have various electronic components 7. For example, a scanning device 9, for example for scanning barcodes, can be provided in the glove 11, wherein the scanning device 9 can likewise be operated via a switching device 8 integrated in the glove 11.
[0058] FIG. 7 illustrates an example of a production method according to the present disclosure for producing an orthosis 10 (cf. FIG. 6). A fabric layer 2 is provided 2a in an FFF/FDM 3D printer 1 by being secured in a platform of the 3D printer 1 such that slipping of the fabric layer 2 during the printing operation 20, 22 (cf. FIG. 8) is inhibited. A 3D printing material 3 is likewise provided 3a by inserting a filament spool 3 into the 3D printer 1.
[0059] FIG. 8 shows a method flow chart pertaining to an example of a production method according to the present disclosure for producing an orthosis 10 (cf. FIG. 6). Initially provided 1a, 2a, 3a, 7a are a 3D printer 1, a fabric layer 2, a 3D printing material 3 and, if appropriate, additional inserts, in particular non-3D-printable electronic inserts 7. After the fabric layer 2 has been inserted into the 3D printer 1, the 3D printing material is applied, in a first printing operation at 20, to the fabric layer 2 in order to form a 3D printed layer 4 (cf. FIG. 2). If appropriate, this first printing operation 20 can be interrupted by a pause at 21 such that, for example, electronic inserts 7, switching devices 8, scanning devices 9 and, if appropriate, further fabric layers 2 can be inserted. The 3D printing is then continued in a second 3D printing operation at 22. After completion of the 3D printing operation at steps 20 and 22, the orthosis 10 can be removed at 23, finished at 24, for example by cutting the fabric layer 2 to size along a contour 5 (cf. FIG. 3a), and then made ready by subsequent sewing.
[0060] Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.
[0061] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”
[0062] The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.
