The biomechanical effects of 3D-printed ankle-foot orthosis in individuals with unilateral foot drop.

Thermoplastic ankle-foot orthotics (AFOs) effectively manage foot drop but are time-intensive to fabricate, while 3D printing offers a faster, customizable alternative with promising early results. However, broader adoption requires further clinical evidence on biomechanical efficacy and user satisfaction, particularly for novel 3D-printed AFOs. This study compared the biomechanical effects of a 3D-printed ankle-foot orthosis (3D-AFO) with a standard thermoplastic AFO (S-AFO) during walking in individuals with unilateral foot drop and evaluated user satisfaction. Nine participants were assessed while walking barefoot, with S-AFO and 3D-AFO conditions. Gait was analyzed using a three-dimensional optical motion-capture system, and satisfaction was measured using the Quebec User Evaluation of Satisfaction with Assistive Technology (QUEST 2.0). The 3D-AFO significantly increased walking speed (0.62 v.s. 0.42 m/s barefoot; p = 0.040) and improved satisfaction regarding device dimensions (p = 0.014) and comfort (p = 0.020). SPM analysis showed both AFOs improved ankle kinematic symmetry during initial and terminal swing phases, with no significant differences at the hip or knee. Overall, the 3D-AFO improves patient satisfaction, walking speed, and ankle kinematics compared to barefoot walking. These results demonstrate that 3D-AFOs are a clinically viable and effective alternative to traditionally made S-AFOs for individuals with unilateral foot drop.