Clubfoot is a complex, congenital deformity of the foot. Its treatment technique with the most scientific evidence supporting its effectiveness is the Ponseti method. This method uses several plaster casts for its correction. We suggest that we can replace plaster casts with pre-simulated 3D printed cast for better and safer treatments. We also automated 3D modeling process from unedited mesh data with computational modeling.

1. 3D Printed Ponseti Cast
3D ALGO. LAB INC.
Keimyung University Dongsan Medical Center
Jan 28th, 2019
DISCLAIMINATION: Actually, to simulate clubfoot correction with Ponseti method, foot’s anatomical kinematics should be considered properly and be
verified by skilled orthopedic surgeons. Currently we’re studying on this subject. It’s still under study. So this content is close to some concept level.

2. Clubfoot
• Clubfoot is a complex, congenital deformity of
the foot also known as ‘congenital talipes
equinovarus’ (CTEV) caused by the abnormal
development of a baby’s bones, ligaments and
muscles whilst in the womb
• Around the world, 150,000 – 200,000 babies
with clubfoot are born each year.
• Without treatment, the clubfoot deformity causes
a lifetime of disability as the affected individual
experiences pain and difficulty in walking. People
with untreated clubfoot find it difficult to access
education, employment and experience exclusion
from society. [1]

3. The Ponseti Method
• Most orthopedic surgeons agree that the primary treatment for clubfoot in young children should be
conservative. The treatment technique with the most scientific evidence supporting its effectiveness
is the Ponseti method.
• Compared to surgical and other conservative techniques, the Ponseti method has been found to
have the best long term outcomes. Over the past decade Ponseti management has become
accepted throughout the world [as the most effective and least expensive treatment of clubfoot.
Ignacio Ponseti Vives, MD [2]

4. The Ponseti Method
• The Ponseti method uses gentle, manual manipulation of the foot, followed by application of
toe-to-groin plaster casts. The casts are changed weekly after a clinician manipulates softened
foot ligaments to gradually achieve near-normal muscle and bone alignment. [1]

5. Problem of Plaster Casts
• Casts are changed 5~6 times, but cast removal process is not easy for babies. Sometimes get
hurt during cast removal processes.
• Bad Smell, Injury of skin, sores and etc.
• We need sufficiently trained orthopedist to do it right.

6. 3D Printed Ponseti Cast
• Jake Evill suggested 3D printed cast 2013, But this is only for immobility not for correction. [3]
• We suggest 3D printed cast for the Ponseti Method with 3D CT based simulation & modeling.
• Washable, Easy Removal, No smell and light weight
• Shorten its treatment time and simplify the whole processes.
• With simulated foot deformation, more accurate cast could be made before starting treatment.
Foot deformation simulation,
- Provided by Materialize Mimics team.

7. Classic Ponseti Method
3D Printed Ponseti Cast

8. Features of 3D Printed Ponseti Cast
• 3D Modeling from mesh data process need some skill and time.
• We automated whole modeling process with Computational or
Algorithmic(Parametric) modeling, using Rhino v6 + Grasshopper
• Minimal Input: Just Parting Curve, boundary curves and thickness
• Shorten modeling time from 1 hours to 1~2 minutes
• As modeling with Loft based NURBS curves & surface,
• print-ability-proof,
• very elaborate model generation is possible near to models by human engineers
• Don't need mush mesh preparation like cleaning or remeshing.
• Automatic Venthole & Locking structure generation
• For the skin contact, whole contact area of models are rounded.
Set boundary & parting curve
Computational Modeling & Preview
Rendered model

9. About Us
• Lee Si Wook, Medical Advisory
 Assistant Professor
 Dept. of Orthopedic Surgery
 Keimyung University, School of Medicine, Dongsan Medical Center
 Specialty: Foot disease and anomaly, Pediatric orthopedics, Glycosuria foot
• Jaeyoon Jeong, Design & Programming
 M.S. in Mechanical Engineering, at Sogang University.
 INUS Technology(now 3D Systems Korea)
 3D AlgoLab Inc. CEO (current)
• 3D Algo. Lab. Inc
We’re studying & developing innovative orthopedic medical devices with
Additive Manufacturing Technology(3D Printing) and AI. Our short-term
mission is to develop needed technologies to spread 3D printed
orthopedic devices for patients’ health & happiness.

10. Reference
• [1] GLOBAL CLUBFOOT INITIATIVE, https://globalclubfoot.com
• [2] The Ponseti Method, https://en.wikipedia.org/wiki/Ignacio_Ponseti
• [3] CORTEX, https://www.evilldesign.com/cortex