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Ankle Splint

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MOST Delta filament as guide.JPG This page was part of an MTU course MSE4777 OA and MSE4777 OB/MSE5777/EE4777/EE5777: Open-source 3-D printing

Please leave comments using the discussion tab. The course runs in the Fall semester. It is not open edit.

Parametric Ankle Brace[edit]

Project developed by Srschroc (talk) 19:08, 4 December 2019 (UTC) and Lacarste (talk) 01:55, 5 December 2019 (UTC)
This OSAT has been prototyped.


IMG 2298.jpg
IMG 2294.jpg

  1. This ankle brace is designed to be stronger and more versatile than other OS ankle braces available online. Most notably, this brace does not require any heat forming where most others do. With proper wrapping, this brace will allow the wearer to walk with an injured ankle. The following picture is the first iteration of the design, which has been updated to be thinner and have more cutouts to decrease print time.
  2. Picture of physical print can be seen to the right.

Bill of Materials[edit]

Part No. QTY Part Desc. Source File STL File
1 1X Base, Ankle Brace [Source files] [Stl files]
2 1X Leg Support, Ankle Brace [Source files] [Stl files]
3 1X Foot Support, Ankle Brace [Source files] [Stl files]
4 1X Lace, Ankle Brace Minimum requirement of 5ft (1.5m) of lace or string like material to be used. [$6 for 328ft (100m) of twine]
5 1X Wrap, Ankle Brace Any material to provide comfort between ankle and cast can be used. Examples of materials can be, medical gauze, old clothing, paper, hay, etc.. Cost is minimal as any of the provided examples can be accessible.

Tools needed for fabrication of the OSAT[edit]

  1. MOST Delta RepRap or similar RepRap 3-D printer
  2. Lace; See BOM above
  3. Soft material for wrapping under brace; See BOM above

Skills and Knowledge Necessary to Make the OSAT[edit]

  • For Adjustability of this ankle brace, it is useful to have a basic understanding of Openscad.

Technical Specifications and Assembly Instructions[edit]

  1. Adjust the shell pieces of the brace to fit the user's foot as needed. Use the openscad files linked in the BOM.
  2. Print off rigid shell pieces of the brace. Use a minimum of 60% infill. For an adult, it is recommended to use 75-85%.
  3. Total print time is estimated to be 26 hours for all three parts.
  4. It takes approximately 5 minutes to wrap the foot in cloth etc and 5 minutes to lace up the brace.

Common Problems and Solutions[edit]

The most common problem is correctly sizing the brace to the user. For comfort's sake, it is better to print a bit too big and use extra wrapping inside the shell to avoid harsh contact with the rigid shell.

Cost savings[edit]

  1. Approximate printing cost for average adult male ~ $10 USD. Cost of shoelace ~ $0.50 USD. Cost of old fabric, cloth, or paper ~ free or minimal.
  2. Commercial equivalent: $60 to $80 USD Brace on Amazon
  3. Cost savings: $50 - ($10 + $0.50) = $39.50

Benefited Internet Communities[edit]

These links provide access to companies supporting small research camps in remote locations and would benefit from this OSAT Design:

Embracing The World

Volunteer HQ

Agape Volunteers

Go Overseas

Volunteering Solutions


The OpenSCAD CheatSheet is very valuable for creating or editing parts in OpenSCAD.