Development of joints suitable for orthoses made of composite materials

Purpose and goal

The objective of the project was to develop joints for orthoses manufactured out of composite materials. The aim was to develop joints that can be integrated in the composite material, i.e. joints that consist of the same material as the rest of the orthosis, to reduce the weight as much as possible. A joint concept, based on carbon fiber-reinforced epoxy, has therefore been developed and tested. The new concept is 50% lighter than the steel joints that are used today, and the manufacturing is both faster and safer. The aim of the project can, therefore, be considered to be fulfilled.

Results and expected effects

A joint concept, based on carbon fiber-reinforced epoxy, has been developed and tested. The new concept is 50% lighter than the steel concepts that are used today, it has better aesthetics (possible to manufacture joints that follow the body more closely), it has shorter manufacturing times, and it is more robust since it contains fewer parts. As the new concept offers a number of benefits compared to the steel concepts that are used today, the plan is to continue with clinical trials and maybe also commercialization.

Approach and implementation

In the initial part of the project, participants from Skandinaviska Ortopedtekniska Laboratoriet and Södra Älvsborgs Sjukhus, put together a requirement specification for orthoses. Then, a number of meetings were organized and a concept for integrated joints was developed. Based on this concept, a prototype joint was manufactured. Unfortunately, this joint was too heavy and the manufacturing technique not completely satisfactory. The concept was, therefore, modified in two steps and new joints were manufactured and tested, before the concept fulfilled all requirements.