Abstract: An additively manufactured ankle-foot orthosis. The ankle-foot orthosis includes an additively manufactured footplate and a calf cuff separate from the additively manufactured footplate. A pre-fabricated strut connects the additively manufactured footplate to the additively manufactured calf cuff and includes thickness and width adapted to define a patient-specific stiffness about an ankle joint of a patient. The stiffness of the pre-fabricated strut is suited to one or more of a gait need or a gait requirement of each patient, and the additively manufactured footplate has a portion with a shape complementary to a shape of a portion of the pre-fabricated strut. So configured, a collective shape and volume of the additively manufactured footplate and the pre-fabricated strut together are adapted to fit inside a shoe of the patient.

Abstract: Disclosed are three-dimensional parts, such as orthotics and prosthetics, having sinusoidal wave pattern infill structures first and second boundary walls. Also disclosed are printers or systems configured to manufacture such parts, as well as methods of manufacturing such parts. The sinusoidal wave pattern infill structures are formed between, and normal to, the first and second boundary walls and are configured to provide locally tunable structural properties in different regions of the part.

Abstract: Disclosed are three-dimensional parts, such as orthotics and prosthetics, having sinusoidal wave pattern infill structures first and second boundary walls. Also disclosed are printers or systems configured to manufacture such parts, as well as methods of manufacturing such parts. The sinusoidal wave pattern infill structures are formed between, and normal to, the first and second boundary walls and are configured to provide locally tunable structural properties in different regions of the part.

Abstract: Disclosed are three-dimensional parts, such as orthotics and prosthetics, having sinusoidal wave pattern infill structures first and second boundary walls. Also disclosed are printers or systems configured to manufacture such parts, as well as methods of manufacturing such parts. The sinusoidal wave pattern infill structures are formed between, and normal to, the first and second boundary walls and are configured to provide locally tunable structural properties in different regions of the part.