Customization and topology optimization of compression casts/braces on two-manifold surfaces.

This paper applies the topology optimization (TO) technique to the design of custom compression casts/braces on two-manifold mesh surfaces. Conventional braces or casts, usually made of plaster or fiberglass, have the drawbacks of being heavy and unventilated to wear. To reduce the weight and improve the performance of a custom brace, TO methods are adopted to optimize the geometry of the brace in the three-dimensional (3D) space, but they are computationally expensive. Based on our observation that the brace has a much smaller thickness compared to other dimensions and the applied loads are normal forces, this paper presents a novel TO method based on thin plate elements on the two-dimensional manifold (2-manifold) surfaces instead of 3D solid elements. Our working pipeline starts from a 3D scan of a human body represented by a 2-manifold mesh surface, which is the base design domain for the custom brace. Similar to the concept of isoparametric representation, the 3D design domain is mapped onto a two-dimensional (2D) parametric domain. An Finite Element Analysis (FEA) with bending moments is performed on the parameterized 2D design domain, and the Solid Isotropic Material with Penalization (SIMP) method is applied to optimize the pattern in the parametric domain. After the optimized cast/brace is obtained on the 2-manifold mesh surface, a solid model is generated by our design interface and then sent to a 3D printer for fabrication. Compared with the optimization method with solid elements, our method is more efficient and controllable due to the high efficiency of solving FEA in the 2D domain.