Open AFO (Ankle-Foot-Orthotic)

This is the Open AFO. We designed this as an improved, custom-fit version of professionally-made AFOs because we think these should be affordable for everyone and because we think the AFO should fit/conform to the person's foot.

We used TPU, but this could easily work with PLA or ABS materials.

Update 16 Apr 2023: Added an example SMO file in a small size. This will have to be scaled up at printing.

Update 18 Nov 2021: Uploaded the STL for the hinge. We attempted two types of hinges:

1. We re-used a set of hinges from a commercial pair of old AFOs. Unfortunately, these hinges can't be purchased directly because of medical patents.
2. We printed some hinges using TPU filament. Varying wall thickness and infill changed how stiff the hinges are and you might have to do some trial and error iterations to make it work for your application.

Update 18 Nov 2021: added IGES files if someone wants to edit the CAD.

Also, original CAD can be found here:
https://cad.onshape.com/documents/eaa0ff8d8d6d4724ec6f512c/w/e2e3304fa6ddf57926478751/e/06069fb59e613e9ada8e0eef?renderMode=0&uiState=6196daea20d5533762950d0f

Slicer Settings:
Layer Height: 0.2mm
Infill: 40-100%
Extruder Temp: 215C
Bed Temp: 70C
Nozzle: 0.6mm
Print Speed: 20mm/s
Rafts: Yes
Supports: Tree

Print the v8_splits or v9_splits for the lower half.
Print the v8_upper for the upper half.

Mirror and repeat.

For more information see https://www.everystepdesigns.com