Abstract
INTRODUCTION: Computer-aided design and manufacturing (CAD/CAM) methods have gained prominence in early orthotic provision. This study introduces an innovative approach using compact three-dimensional (3D) printers and computed tomography data to generate segmented body models for traditional Damen corset orthoses. The goals included evaluating the comfort and fit of orthoses and assessing the effectiveness of our approach for prosthetic companies with limited financial resources. MATERIALS AND METHODS: Lumbar and thoracolumbar orthoses were crafted via CAD/CAM. Four healthy patients wore the orthoses, with whom immediate and 1-week comfort and fit assessments were conducted. A prosthetist assessed fit, and the Japanese edition of OPUS-CSD, the Orthotics Prosthetics Users' Survey-Client Satisfaction with Device, was used for subjective assessment of comfort and fit. RESULTS: The fit evaluations were satisfactory for all patients with positive predefined criteria. Questionnaire responses confirmed high satisfaction and comfort, confirming a successful orthosis fit. CONCLUSION: We established an orthotic fabrication method using CAD/CAM methods with 3D printers. Additionally, we confirmed the comfort and fit of the corsets so produced. The initial cost of 3D printers is lower than that of traditional carving machines, enabling even small-scale orthotic fabrication facilities to utilize CAD/CAM methods. Further research and refinements of this manufacturing approach are expected to expand its applicability.