Force Characterization and Manufacturing of a Dynamic Unilateral Clubfoot Brace

Clubfoot is a musculoskeletal birth defect characterized by an inward twisting of an infant’s feet. Currently, a series of casts are used to correct the clubfoot, and a boots-and-bar brace is used to maintain the correction. However, this method has concerns with compliance, comfort, and social stigma. Hope Walks and their clinic in Kijabe, Kenya are interested in implementing a new maintenance brace that addresses these concerns. Mr. Jerald Cunningham, CPO, designed and is utilizing a unilateral clubfoot maintenance brace called the Cunningham Clubfoot Brace. He asserts his brace reduces treatment time, lessens social stigma, and increases child mobility. However, to date, there is not enough published research on its biomechanics and patient success rates to confirm his findings. The Cunningham Clubfoot Brace Collaboratory project seeks to validate the effectiveness of the Cunningham design through biomedical testing and increase brace availability through sustainable manufacturing. To do this, the team is measuring the biomechanical forces applied by the brace with multiple force sensor systems and an infant foot model. The team is assisting Mr. Cunningham in his plans to use injection molding to increase brace production by scanning and creating CAD files of the brace. The team is also completing a failure and reuse analysis of the Cunningham Brace for the clinic in Kijabe. Furthermore, the ongoing clinical study at CURE International\u27s hospital in Kijabe, Kenya, and Dr. Emily Farrar’s research paper will provide greater insight into the effectiveness of the Cunningham Brace. These collaborative efforts will allow for further understanding of the effectiveness of the Cunningham Brace and its acceptance as an alternative clubfoot maintenance brace.https://mosaic.messiah.edu/engr2021/1001/thumbnail.jp

Force Characterization and Manufacturing of a Dynamic Unilateral Clubfoot Brace

Clubfoot is a musculoskeletal birth defect characterized by an inward twisting of an infant’s feet. Currently, a series of casts are used to correct clubfoot and the Steenbeek brace is used to maintain the correction. However, this method has issues with compliance, comfort, and social stigma. Mr. Jerald Cunningham, CPO, designed and is utilizing a unilateral clubfoot maintenance brace called the Cunningham Clubfoot Brace. He expects his brace to reduce treatment time, lessen social stigma, and increase child mobility. Hope Walks, in Kijabe, Kenya, is interested in implementing this new maintenance brace at their clinics. However, there is not enough published research on its biomechanics and patient success rates to confirm Mr. Cunningham’s findings. The Cunningham Clubfoot Brace Collaboratory project seeks to validate the effectiveness of this design through biomedical testing and increase brace accessibility through sustainable manufacturing. The team is measuring the biomechanical forces applied by the brace with multiple force sensors on the Cunningham and Steenbeek braces. Mr. Cunningham plans to use injection molding to increase brace production. The team is completing Finite Element Analysis to determine how the brace’s properties change with injection molding. The team is also completing fatigue analysis with the Cunningham Brace to quantify its reusability. Furthermore, the clinical study in Kenya and Dr. Emily Farrar’s retrospective research paper will contribute to the published research on the Cunningham Brace. The collaborative efforts of the team will increase further understanding of the Cunningham Brace and its acceptance as an alternative clubfoot maintenance brace.https://mosaic.messiah.edu/engr2022/1002/thumbnail.jp

Prosthetic Knee

Amputations, specifically lower limb amputations, are common in Sub Saharan Africa and across the broader global community largely due to infection and disease. Our project, The Prosthetic Knee Team, partners with the orthopedic workshop at the CURE International Hospital in Kijabe, Kenya to create a prosthetic knee design for a specific type of amputation known as a Knee Disarticulation (also called through-knee). Currently, the orthopedic workshop is only able to provide one very expensive prosthetic knee option for these patients, and they often elect to undergo a second surgery, a trans-femoral amputation, because the cost of the second surgery and trans-femoral prosthesis combined is less than the currently available through-knee prosthetic. The goal of our project is to provide the orthopedic workshop with a manufacturable prosthetic knee design that provides through-knee amputees with a cheaper prosthetic option and removes the need to have a second amputation above the knee. Throughout the past two semesters, our focus was on organizing collected data, researching knee-disarticulations, and communicating with our client to more fully understand the scope of our project. After determining that moving forward our project will be manufacturing the prosthetic knees at Messiah College’s machine shop and shipping them to CURE Kenya to be fit on patients, we began to brainstorm potential design ideas. We are presently working on modifying and improving our chosen design to best meet all of the specifications laid out by our partner. Those specifications include minimized thigh-lengthening, low weight, maximized stability and durability, and aesthetically pleasing.https://mosaic.messiah.edu/engr2020/1017/thumbnail.jp