Practicing Topology Optimization Workflow for Structural Simulation and Customized Splint Fabrication

Topology optimization tolls are becoming effectively more useful across a variety of designing and manufacturing sectors, due to their capability to produce performance oriented lightweight configurations. Especially when the target is to deal with the complex user specific diaphanous products, the integrity of additive manufacturing with such design optimization techniques introduces the practicality in the application. This paper focuses on how the structural simulation in the early design phases can make a splint more comfortable for the user, without compromising its strengthening properties. A custom finger-splint has been designed using 3D scans, processed under structural simulation followed by topology optimization and validation and then fabricated from additive manufacturing using PLA (Polylactic acid). The optimization results show a considerable weight reduction (3.524 gm for 60% retained mass) of 30.52 % from the un-optimized one (5.072 gm for 100% retained mass). Also, removing access material can assure the ventilation ease to the limb and provide the user with sweat-free comfort.