Research on Design and Topology Optimization of Personalized Scoliosis Orthopedic Device
Institute of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, China
| Abstract: | The incidence of adolescent idiopathic scoliosis (AIS) is on the rise. Clinically, conservative treatment usually involves wearing spinal orthoses. However, traditional orthoses are bulky, which adversely affects patient tolerance and quality of life. Therefore, the development of personalized, lightweight spinal orthoses that also take into account mechanical performance holds significant practical value. Based on 3D-scanned trunk data, the designs of the iliac crest, three-point force application areas, and relief zones are completed through deviation analysis and X-ray-model registration. A finite element model is established to simulate the mechanical responses under two states: wearing the orthosis and applying an opening force. By comparing four material removal rate schemes, the "50% material removal scheme" is identified as the optimal initial-stage scheme. Based on the optimization results, the left iliac crest is further selected as the optimization area for secondary topological optimization. The results show that the secondary topological optimization achieves an additional 6.7% weight reduction compared to the "50% material removal scheme," resulting in a total weight reduction of 41.6%. The maximum stress is 46.63 MPa, and the maximum deformation in the orthotic region is 0.74 mm, both of which meet the design requirements. This study provides a reference for the lightweight design of spinal orthoses for patients with specific types of scoliosis. |
| Keywords: | Scoliosis; Orthosis; Lightweight; Topological Optimization; Reverse Engineering |
| DOI: | 10.57237/j.wjcm.2025.04.001 |
View:
Downloads:
Received: 29 November 2025
Accepted: 25 December 2025
Published Online: 30 December 2025
Funding
| 1. | Natural Science Foundation of Liaoning Province (Grant No. LJKMZ20220841) |
References
| [1] | Del Prete C M, Tarantino D, Viva M G, et al. Spinal orthosis in adolescent idiopathic scoliosis: an overview of the braces provided by the National Health Service in Italy [J]. Medicina, 2023, 60(1): 3. https://doi.org/10.3390/medicina60010003 |
| [2] | Jing W, Jin Z, Rui X, et al. Measurement of scoliosis Cobb angle by end vertebra tilt angle method. [J]. Journal of orthopaedic surgery and research, 2018, 13(1): 223. https://doi.org/10.1186/s13018-018-0928-5 |
| [3] | Ogilvie J. Adolescent idiopathic scoliosis and genetic testing [J]. Current opinion in pediatrics, 2010, 22(1): 67-70. https://doi.org/10.1097/MOP.0b013e32833419ac |
| [4] | Simhon M E, Fields M W, Grimes K E, et al. Completion of a formal physiotherapeutic scoliosis-specific exercise training program for adolescent idiopathic scoliosis increases patient compliance to home exercise programs [J]. Spine Deformity, 2021, 9(3): 691-696. https://doi.org/10.1007/s43390-020-00253-8 |
| [5] | Minsk MK, Venuti KD, Daumit GL, Sponseller PD. Effectiveness of the Rigo Chˆeneau versus Boston-style orthoses for adolescent idiopathic scoliosis: a retrospective study [J]. Scoliosis and Spinal Disorders 2017; 12(1). https://doi.org/10.1186/s13013-017-0117-z |
| [6] | Weinstein SL, Dolan LA, Wright JG, Dobbs MB. Effects of Bracing in Adolescents with Idiopathic Scoliosis [J]. N Engl J Med 2013; 1512-1521. https://doi.org/10.1056/nejmoa1307337 |
| [7] | Wei W, Zhang T, Huang Z, et al. Finite element analysis in brace treatment on adolescent idiopathic scoliosis [J]. Medical & Biological Engineering & Computing, 2022, 60(4): 907-920. https://doi.org/10.1007/s11517-022-02524-0 |
| [8] | IASON ROSSETOS, CHARIS J. GANTES, GEORGE KAZAKIS, et al. Numerical Modeling and Nonlinear Finite Element Analysis of Conventional and 3D-Printed Spinal Braces [J]. Applied Sciences, 2024, 14(5). https://doi.org/10.3390/app14051735 |
| [9] | Liao Y C, Feng C K, Tsai M W, et al. Shape modification of the Boston brace using a finite-element method with topology optimization [J]. Spine, 2007, 32(26): 3014-3019. https://doi.org/10.1097/BRS.0b013e31815cda9c |
| [10] | Cobetto N, Aubin C E, Parent S, et al. Effectiveness of braces designed using computer-aided design and manufacturing (CAD/CAM) and finite element simulation compared to CAD/CAM only for the conservative treatment of adolescent idiopathic scoliosis: a prospective randomized controlled trial [J]. European spine journal, 2016, 25(10): 3056-3064. https://doi.org/10.1007/s00586-016-4434-3 |
| [11] | Tz-How H, Chi-Kung F, Yih-Wen G, et al. Optimization design of thumbspica splint using finite element method. [J]. Medical & biological engineering & computing, 2006, 44(12): 1105-11. https://doi.org/10.1007/s11517-006-0131-4 |
| [12] | F S K, A M Z, L T. Lightweight design of Knee-Ankle-Foot Orthotic Devices using Voronoi patterns for Additive Manufacturing [J]. Journal of Physics: Conference Series, 2023, 2643(1). https://doi.org/10.1088/1742-6596/2643/1/012007 |
| [13] | Du Y, Li Y, Wu Z, et al. Research on filtering and measurement algorithms based on human point cloud data [J]. International Journal of Intelligent Systems, 2022, 37(12): 12252-12266. https://doi.org/10.1002/int.23085 |
| [14] | Schlösser T P C, Van Stralen M, Brink R C, et al. Three-dimensional characterization of torsion and asymmetry of the intervertebral discs versus vertebral bodies in adolescent idiopathic scoliosis [J]. Spine (Phila Pa 1976).39: E1159-1166. (2014). https://doi.org/10.1097/brs.0000000000000467 |
| [15] | Majdouline Y, Aubin C E, Robitaille M, et al. Scoliosis correction objectives in adolescent idiopathic scoliosis [J]. Journal of Pediatric Orthopaedics, 2007, 27(7): 775-781. https://doi.org/10.1097/BPO.0b013e31815588d8 |
| [16] | Liu Xiaomei, Zhou Yong, Wang Yanyang, et al. Application of 3D printing technology combined with computer-aided design in the manufacture of scoliosis orthosis [J]. Chinese medical equipment journal, 2023, 44(5): 74-80. https://doi.org/10.19745/j.1003-8868.2023098 |
| [17] | Lu D, Li T, Yu W, et al. Expert consensus on the design, manufacture, materials, and clinical application of customized three-dimensional printing scoliosis orthosis [J]. Digital Medicine, 2022, 8: 2. https://doi.org/10.4103/ digm.digm_34_21 |
| [18] | Zhang, Y. F., Guo, H. W., Lü, M., et al. (2025). Calculation and analysis of scoliosis correction force [J]. Machinery Design & Manufacture, (07), 30-34. https://doi.org/10.19356/j.cnki.1001-3997.20241227.058 |
| [19] | Ren, D., Zhu, Y., Lei, L., & Wang, Y. R. (2022). Finite element analysis of the effect of orthopedic force applied to rib force - application areas on the displacement and rotation angle of the thoracic vertebrae [J]. Chinese Journal of Tissue Engineering Research, 26(18), 2812-2816. https://doi.org/10.12307/ 2022.686 |
| [20] | Lian, W., Wang, H. S., & Yu, J. (2021). Local optimization design of 3D-printed scoliosis orthosis based on finite element analysis [J]. Journal of Medical Biomechanics, 36(06), 855-861. https://doi.org/10.16156/j.1004-7220.2021.06.004 |
| [21] | Curfs I, Rooij V W, Senden R, et al. Evaluating the Immobilization Effect of Spinal Orthoses Using Sensor-Based Motion Analysis [J]. Journal of Prosthetics and Orthotics, 2016, 28(1): 23-29. https://doi.org/10.1097/JPO.0000000000000085 |
| [22] | Clin J, Aubin C E, Parent S, et al. Comparison of the biomechanical 3D efficiency of different brace designs for the treatment of scoliosis using a finite element model [J]. European Spine Journal, 2010, 19(7): 1169-1178. https://doi.org/10.3233/bme-2010-0639 |
| [23] | Grycuk S, Mrozek P. Finite Element Model of Scoliosis Brace with Increased Utility Characteristics [J]. Applied Sciences, 2023, 13(24): 13273. https://doi.org/10.3390/app132413273.2022 |
Join the Editorial Board
We invite active, qualified and high profile scientists and researchers to join as Editorial Board Members.
Join UsBecome a Reviewer
Scholars with a strong interest in reviewing are invited to join the reviewer panel to ensure the quality of the research to be published.
Join Us