A New Method in the Design of a Dynamic Pedorthosis for Children With Residual Clubfoot

Clubfoot is a common pediatric orthopaedic deformity. Despite the popularity of Ponseti’s method and night splints such as the Denis–Browne method, there is still an 11–47% rate of deformity relapse reported in the literature. The technique to make traditional orthotics is dependent on a nonweight-bearing casting or foot imprint. These splints outdate clinical treatment trends and only apply to patients who are of nonwalking age. This study shows that a new procedure utilizing computer aided design and the finite element method can be employed to develop a customized weight-bearing dynamic orthotic. In addition, the plantar pressure distribution and the trajectory of the center of this pressure distribution are used to design the orthotic. It is shown that the trajectory of the center of pressure, traditionally used in gait analysis, can be used not only to quantify the severity of the foot deformity but to design a custom orthotic as well. Also, the new procedure allows the custom orthotic to be designed and analyzed within a day. The new orthotic design is composed of soft foam interior layers and a polymer supportive exterior layer. It is proved that rapid prototyping technologies employing selective laser sintering can be used to construct these layers to produce a custom orthotic within a 24 h time frame.