The 3D-printed LUNA leg brace grows with its user
Targeted at children with Hereditary Spastic Paraplegia, the Luna Ankle Foot Orthosis uses a toolless modular system that adapts as they grow.
LUNA Modular AFO is an innovative ankle-foot orthosis designed by Australian designer Alex Nguyen to support children affected by Hereditary Spastic Paraplegia—a progressive condition that causes stiffness and weakness in the leg muscles, often impairing gait.
Traditional AFOs can quickly become ill-fitting as children grow, leading to discomfort, bruising, and skin irritation. To address this issue, the LUNA Modular AFO features a toolless, modular system made from semi-flexible plastics that adapt to the user’s growth. This thoughtful design softens contact around sensitive areas such as bone protrusions, ensuring a more comfortable and long-lasting fit as the child develops.
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The orthosis consists of two components; a customised LUNA Surface, which wraps around the leg and the foot according to the user. This attaches to the LUNA module, a mass-manufactured component that acts as a base for the device. When the LUNA Modular AFO is deemed too small, a new Surface replaces the existing one.
“The LUNA Surfaces are 3D printed parts designed to be form-fitted to each unique user,” says Nguyen. “Scanning technology is used to digitise the fabrication process, which currently involves complex moulding and casting techniques.”
The Surfaces are 3D-printed in Nylon 11, a semi-flexible bioplastic, which the design process manipulates to soften in sensitive areas. The malleability of the material also offers a useful gauge for understanding when parts are too small in what Hyugen calls the Shapechange Feature.
“[It] empowers the user and their parental guardians to understand the AFO’s fitment and proactively upgrade the AFO rather than regular checks with the orthotists or when the child starts getting AFO related injuries,” he explains.
Last month, the LUNA Modular AFO was awarded the National Winner of the 2021 James Dyson Award because of its innovation within the design sector. It imagines an exciting alternative to common styles of AFOs for children which feature traditional vacuum-formed thermoplastics, which cause pain and user discomfort.
Separating itself from these types of devices, The LUNA AFO’s modular system not only makes for a more user-friendly experience but it extends the life of the product from 6-8 months to several years.
And the benefits don’t just stop there. For professionals and fabricators, the system provides an open platform that utilises a digital process to create more accessible fabrication and more consistent orthoses for their clientele.
About the author
Kieron is a freelance writer and Digital Consultant who doesn't consider himself a design lover but a user of design - which to him is more than enough.
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