FIDIM 3 AFO Leg braces

This is the latest iteration of the FIDIM leg braces. They look very similar to FIDIM 2, but I have made numerous changes. They have been thinned in some areas, and thickened in others. The uppers conform to the wearer's leg better, and the lowers aren't as wide. The heel protrudes more, meaning that they fit in shoes more like an actual foot does. I changed the design of the flexihinges so that they taper with the braces themselves, making the overall brace less bulky. They should be just as strong. The screws now go in at an angle so that the nuts sit flush with the outsides of the braces. The flexihinges have pre-cut holes at the correct angles. I used "Tee-Nut Threaded Inserts" instead of basic hex nuts this time. They distribute the load better, and anchor into place. Just use an old soldering iron to set them in place. They work wonderfully. They're technically for wood, but still work fine for plastic. I used 6-32 screws for these, because I live in the US. Stores with a decent supply of metric hardware don't really exist here, though I do prefer it when I can find it. M3 hardware should work just as well though, if that's what you have available. I have come up with a simple type of steel hinge that doesn't require much in the way of tools to create. I am going to be re-designing these at some point to accommodate those. TPU hinges are nice, but they do introduce some limitations.

My philosophy with these is that I want them to be relatively easy to make, and I want them to be strong enough to not break on me while I am at work. I am not technically "disabled," but being on my feet all day without a little help is extremely difficult. If my braces let me down, I am in for a really rough time. So that's why these might seem a little bulky here or there. I can't have them fail on me.

If you make these for yourself or someone else, please let me know. It would be so great to be able to help someone else that just needs a hand. The world could use a little more kindness.

Printing Instructions:

I again used Overture Easy Nylon for these. It's my favorite filament for strong functional prints. I have an Elegoo Neptune 4 Max now though, so I cranked the extruder temp all the way up to 300C. I want to see how that affects things. No issues with printing. I recommend that you soak the finished parts in water overnight. Dry Nylon is brittle, but it gets flexible once it soaks up some water. Help it along. The lowers do not require supports, but the uppers do. I used rafts for them both. The flexihinges do not require supports, and are printed in Overture TPU 95A. It matters which way you put them on, so I embossed a key on both of them. "O-U" and "I-U" O-U = outer hinge, this end up. I-U = Inner Hinge, this end up.