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

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

3. 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

4. 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

5. 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

6. Design Idea Process

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

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

9. 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

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

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

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

13. Design Procedure

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

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

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

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

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

19. Device Evaluation and Testing

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

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

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

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

24. 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

25. 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

26. Questions?

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