K-Air FOrce Doug Follmer Shubhra Kochar Lauren Levey Adam Zurmehly

Outline Clinical evaluation Initial design process Design procedure Device evaluation and testing Device demonstration Future recommendations Acknowledgements

Spinal Cord Injuries Affect neuromuscular and sensory function below level of injury ~12,000 new injuries per year Shorter life expectancy, higher cost of living

Rehabilitation 4-6 months of outpatient therapy Maintaining and building muscle strength Knee-Ankle-Foot Orthotics T-6 injuries and below Home mobility Highly Customized Acceptance Rate 2008 Article: 58-79% abandoned 40% of remaining users express dissatisfaction http://www.cascade-usa.com/products/ORTHOTICS/LOWER%20EXTREMITY%20ORTHOTICS/FRACTURE%20BRACES/MARAMED%20TIBIA%20FRACTURE%20BRACE%20S-SERIES.aspx

Project Definition Adjustable KAFO for clinical diagnosis Design Requirements Leg size and height adjustments Ankle Support Ability for knee flexion Comfort Fatigue Resistance Image: Picture of KAFO padding

Design Idea Process

Initial Design Thigh: three piece design Shank: two piece design Foot plate Thermoplastics thermoplastics straps Hard plastic

Initial Design Telescoping- steel and Titanium rods Knee and Ankle joints- Ultraflex

Design Process Re-evaluation of components in terms of strength, stability, machinability, adjustability and weight. More research Limitations in available components New ideas Carbon fibers Revisited the previous ideas Improvisation of initial design

Final Design Thigh and shank: One piece design with air pockets and padding

Final Design Knee and Ankle joints Solid Stirrup Knee-joint Orthoamerica Ankle-joint OTS Corp Carbon fiber foot

Final Design Telescoping: Continuous mechanism Adjustment between knee and thigh and shank and ankle

Design Procedure

Positive Mold of the Thigh Thermoplastic Plaster Bandages Plaster of Paris Mold EWI Oven (~ 195˚ C) Positive Mold of the Thigh Thermoplastic (~ 9 min)

Carbon Fiber Carbon Fiber Mold Release Epoxy Resin Hardener Carbon Fiber Feet: Left - First Attempt Right - Second Attempt Assembly

Metal Rods/Telescoping Aluminum Rod: Side View Aluminum Rod: Top View Machined Bracket for Telescoping

Air Pocket Fabrication Air Cast EWI: OSU Welding Engineering Division - Plastic Welding

Assembly Padding / Velcro Ankle Joint Velcro Final KAFO - Side View Final KAFO - Front View

Device Evaluation and Testing

Review of Requirements What’s Important Key Areas Knee Joint Ankle Joint Height/Diameter Adjustment Padding Straps Support Stability Adjustability Comfort Weight Cost

Patient #1: Ben Height: 6’1” Injury: L1 incomplete

Evaluation Patient #2: Perry Height: 5’9” Injury: T10-T11 Complete

Demonstration Thermoplastic Padding Aircells Orthomerica Knee Joint OTS Orthotics Ankle Joint Carbon Fiber Foot

Future Recommendations Non-riveted Velcro strap Knee Joint alterations Lock in extension More strength in bolts Shank adjustment Carbon Fiber Foot Screws Protruding Tools Orthotist

Acknowledgements Dr. David Lee- Machine Shop, Mentor Dr. Mark Ruegsegger- Mentor Heather Loge- D.Physical Therapist, Clinician Mentor Melissa Aston- Physical Therapist, Testing advisor Rowan, Ben, and Perry- Patients, Test Subjects North Sea Plastics- Thermoplastic Donation OrthoMerica- Knee Joint Donation Kirk Cooper, EWI- Thermoplastic forming Dr. Avraham Benatar, OSU: MSE- Plastic Air Pocket Welding Ryan- Scott Labs Machine Shop Rowan, Ben, and Perry- Patients, test subjects Jerry, Hanger Orthopaedics- Ankle Stirrup bending Bruce Chase- Carbon Fiber advice Rob Kapaku- Team Name Punnery

Questions?

Resources Otto, Judith Phillipps. “The Stance Control Orthosis: Has Its Time Come?” The O&P Edge. Online article