Eco-friendly innovation: Enhancing orthotic production with additive manufacturing

This study explores the integration of Additive Manufacturing (AM) and Finite Element Analysis (FEA) to support the design and evaluation of lower-limb orthotic devices, with a particular emphasis on sustainability and digital fabrication efficiency. Recycled Acrylonitrile Butadiene Styrene (ABS) was selected as a feasibility-driven material to demonstrate the potential for circular-economy practices in orthotic production. A reproducible workflow combining anatomical 3D scanning, CAD modelling, FEA simulation, and mathematical performance modelling was developed to compare AM with traditional manufacturing methods. Production and material-efficiency models indicate that AM can reduce overall fabrication time, minimise material waste, and improve resource utilisation when compared with conventional approaches. The mechanical performance outcomes—including stress distribution and deformation behaviour—are derived exclusively from finite-element simulations and should be interpreted as predictive mechanical indicators requiring further validation through bench testing and clinical evaluation. The findings demonstrate that AM enables digitally optimised geometries and efficient material placement, supporting both customisation and sustainability objectives. This research contributes a structured, simulation-supported framework for orthotic design using recycled materials, highlighting the potential of AM-FEA integration to advance personalised, resource-efficient medical device manufacturing.