Computerised rapid prototyping of human foot using computed tomography

Rapid prototyping (RP) is an additive manufacturing process where the prototype is built layer by layer according to the three-dimensional (3D) contours data of the model. The human foot is considered to be a complex load bearing member and to study it, a realistic representation is needed. The stress distribution in the foot depends on geometry and structure of the foot. The purpose of this paper is to describe the building of 3D prototype of the human foot from CT scan data and hence, to assist in pre-surgical planning of foot. The digital CT scan data of the human foot were acquired and processed in MIMICS s/w and 3D computational model of the foot was developed. The RP model of the foot was then built using polymeric ABS material in fused depositional modelling (FDM)-1650 RP system. The built prototype depicts the true geometry of the human foot. The study helps in understanding the foot and ankle joint anatomy. The prototype is useful for preoperative surgical planning, surgical simulation and is also useful for production of customised implants.