Design Analysis and Manufacturing of Knee Ankle Foot Orthosis

Project Title

Design Analysis and Manufacturing of Knee Ankle Foot Orthosis

Project Area of Specialization Mechanical EngineeringProject Summary

A Knee Ankle Foot Orthosis or KAFO is a lower extremity orthotic that is used to control instabilities in the knee and lower limb by maintaining proper alignment and controlling motion. Quadriceps weakness can be primarily caused by neurological diseases and muscular diseases, such as post-polio syndrome, spinal cord injury, trauma, multiple sclerosis, muscular dystrophy, unilateral leg paralysis and paresis. A person with such neuromuscular disorders has limited ability to perform knee extension, while normal quadriceps contracts to produce knee extension and contracts to control knee flexion.

Braces that make up KAFOs are imported from European countries, carrying a high price tag, thus making these unaccessible to the majority of Pakistanis. Idea is to design and produce these locally.

Project Objectives

The aim of the project is to design and manufacture braces, that make up the structural part of KAFOs, locally in Pakistan. Even though KAFOs have been around for years, supporting millions of differently abled in their day to day tasks, in Pakistan like a lot of other things, these is still no attention paid to their local manufacturing and thus are being imported from abroad. This results in not only an increased cost of these KAFOs, but also adds up to our nation's dependency on foreign countries and results in higher import bill.

Thus locally manufactured KAFOs will not only reduce the product cost but can also be exported to other countries to compete with same quality but costly availaible models.

Project Implementation Method

A basic literature review along with market survey has been performed to narrow down the project deleiverables and to prepare a feasibility report. Based on this a project plan has been devised. Some visual observations such as dimensions, type and connection of joints have been made from existing model thanks to a local rehablition center on the basis of which CAD model is designed with suitable modifications.

Only a rough and initial FEM analysis is possible at this stage as FEM analysis requires actual force data, which can be obtained by testing on actual model and breaking it apart. It can only be possible if we procure/ buy the model from Rehabilition center. 

Based on the CAD model and FEM Analysis 3-4 prototypes can be developed by procuring the required material and machining it to the desired shape and size. These prototypes can then be used for actual lab testing and if according to the internationally approved stndards, human testing can be done under strictally controlled enviornment. 

After receiving the nod from the local rehabilition centers, a mass production plan may be devised with the collaberation of loca and industry as well as medical and rehabilition centers. Initial funding target can be  acheived by marketing the idea to various local and imterntional NGOs and relevant government departments. The design and manufacturing process will not be patented to encourage further research and development and to avoid monoply.

Benefits of the Project

Braces, being imported are only affordable to upper and middle class. However majority of our population that needs these KAFOs hail from lower class (monetarily) and thus require a cost effective but quality tool for their everyday mobility.

These braces will compete with imported ones with same quality but at a much lower cost. These braces will be produced locally and due to lot less labor cost, no freight or custom charges and no charges for the label "Swiss Made", the cost will reduce substantially, thus making these accessible to all.

Technical Details of Final Deliverable

Braces, as a part of KAFOs, prevent legs from bending while standing by locking the brace joint, thus supporting the body load. While sitting, the lock is undone manually allowing legs to bend normally. The end product should be able to withstand all the forces including body load, lateral forces due to leg movement etc. without yielding. Also the material selected shoul have high strength and rigidity but preferably low density to reduce net weight of KAFOs. 

Another important thing is the type of joint and connections used to imitate the human knee joint and the forces on the lock that will prevent the rotation of braces. 

Final Deliverable of the Project Hardware SystemCore Industry MedicalOther Industries Manufacturing , Health Core Technology Wearables and ImplantablesOther TechnologiesSustainable Development Goals Good Health and Well-Being for PeopleRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	39800
Procurement of existing model for testing and study	Equipment	1	18000	18000
Prototype development	Equipment	4	5450	21800