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Engr 110 Final Presentation .pdf



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Fairing Well
Anna Olson, Jess Moss, Lisa Su
ENGR 110 Final Presentation
8 March 2016

Problem Statement

prosthetic = artificial limb to replace a missing one

orthotic = bracing an existing part of the body

there are solutions for functional deficiencies in limbs, but none for
aesthetic damage
the psychological impact of a disfigured limb’s appearance affects one’s
ability to live a normal life
some products (“fairings”) exist and address this for prosthetic limbs, but
none for orthotic braces

Project Suggestor & Future User Interviews
Max Conserva:

engineer, athlete, and
adaptive athletics advocate
working to solve
unaddressed challenges
from own condition and
share those results with
others
www.goodleg.org

Identification of Need
Max’s right leg is
functional with its
brace, but noticeably
deformed.
the need: an orthotic
fairing to interface
with Max’s existing
brace and visually
improve the
appearance of his
right leg

Existing Solutions
UNYQ

Bespoke Innovations
altLimbPro

Fairing Well process

Initial Brainstorming & Design Concepts

shapes
mounting to brace
materials & manufacturing

early prototypes
grid-scored cardboard//\\SAM splint

approximation of shape & dimensions
seams & interfacing
importance of lines

challenge: how do we manufacture this at the next
level of resolution?
-

rigid model of an organic 3D surface
eventually a layup or thermoform process, requiring a mold
additive mold manufacture was more cost effective

solution: mold manufacturing & thermoform process
-

developed leading up to midterm presentation
→ manufacturing prototype / proof of concept
second iteration for final brace shape
- incorporated learnings from first attempt
- edits to shape & process

replicating in CAD

measurements from prototypes
SolidWorks surfacing tools
split into sections for lasercutting
changed shape in CAD for round 2

mold manufacture: duron stacks

improvement:
mold alignment features

mold manufacture:
bondo

mold manufacture:
sanding

thermoforming

next step: implementation
-

finalize shape
test and select final material
develop fasteners for rigid attachment to brace
produce final iteration

finalizing shape

more bondo + sanding to change mold shape
thermoform each iteration
trim thermoform plastics to fit brace

updated CAD / mold shape:
increased wrap-around
less curvature

fastener brainstorming

fastener prototypes:
custom plastic clips

velcro attachment

invisible from outside
quick on/off
tool-less
reliable
rigid attachment

final material

1/8” thermoform opaque black ABS
sufficient rigidty vs. 1/16” plastic

final shape & trim to fit brace
bandsaw, (dremel), sanding

finish: bead blast with
vinyl logo masking

cost to build:

plastic sheet, duron for mold,
bondo, velcro, sandpaper: $26

aesthetics: achieves goal

safety: does not inhibit
movement
non-structural component
tradeoffs: non-permanent
fasteners
material & ease of manufacture

in the future:
-

use positive plugs to make a negative mold
carbon fiber layup
different fastener system
extend fairing around back of leg
document process for Max to continue project in the future
make customizable to other unique orthotics

@goodlegproject
thank you!
thanks to Dave Jaffe & the Stanford
PRL for the opportunity to work on
this project.


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