Pro-O-light – Head Orthosis

Development of an additively manufactured head prosthesis with integrated sensors that can be monitored via telemedicine

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Brief description

Head orthoses are used to correct head deformities in babies and young children over a period of several months. They are painstakingly crafted from thermoplastic material. With current technology, the fit of these head orthoses can only be monitored to a very limited extent during the course of treatment. As a result, complications caused by pressure peaks and moisture occur in more than one in five children. The planned project aims to develop a method for integrating sensors for pressure, moisture and temperature into the 3D Printing process used to manufacture a 2K head orthosis. To achieve this, a suitable head orthosis, as well as an appropriate print head and a gripper system for positioning the sensors during the printing process, must be developed. The major advantage of the new head orthosis lies in its very open, lightweight yet highly secure structure, as well as the integration of a telemedical data readout and evaluation function for the entire sensor system.

Motivation

  • Drastic reduction in production times
  • Quick and individual adjustment of the head braces, based on measurement data
  • Prevention of pressure sores or other complications

Objectives

  • Further development of a customisable slicer for the unconventional 3D-HRD approach
  • Improvement of the 3D printing process on a rotating printing platform
  • Integration of sensor technology during the printing process

Duration

1 July 2022 to 31 December 2024

Funding and project organisers

ZIM – Central Innovation Programme for SMEs, VDI/VDE

Partners

  • Dresden University of Technology – Institute of Lightweight Construction and Plastics Technology
  • Ehnert Mechanical Engineering GmbH & Co. KG, ATZ GmbH Industrial Automation
  • saXcare GmbH

Contact persons

Prof. Dr.-Ing. Jörg Hübler
Prof. Dr.-Ing. Jörg Hübler
FakultƤt Ingenieurwissenschaften