AutoKOOP – Automated Workflow for Patient-Specific Carbon Fiber Reinforced Orthopedic Products
Automated workflow for producing lightweight and customized assistive medical devices through continuous fiber 3D printing.
Project Partners
phoenix GmbH & Co. KG, Sanitätshaus Klein, ArtiMinds Robotics GmbH
Duration
01.10.2024 – 30.09.2027
Funding authority
German Federal Ministry of Education and Research (BMBF)
Motivation
Orthopedic aids, such as orthoses, prostheses and exoskeletons, help people with disabilities by stabilizing joints or supporting their movements. To ensure maximum effectiveness and comfort for patients, it is necessary to meet their specific requirements. However, conventional manual manufacturing methods often struggle to meet the high demands for customization in terms of patient-specific factors, variable stiffness, high strength and lightweight construction. In addition, the current produced parts often suffer from lack of manufacturing standardization, which leads to quality variations. In the AutoKOOP project, we aim to integrate digitalization into the production of prostheses, from patient requirements to finite element modeling and manufacturing, introducing automation of the entire process chain. With the help of advances in carbon fiber reinforcement and topology optimization, we will precisely control the strength and stiffness of the frame in additive manufacturing. This project promises technological innovations that will benefit both patients and healthcare professionals.
Method
As part of the project, the Technical University of Munich Chair of Carbon Composites (TUM-LCC) focuses on the application of carbon composites and the lightweight design of prosthetic sockets. TUM-LCC's work will concentrate on the development of non-planar additive manufacturing process for continuous carbon fiber, enabling the manufacturing of prosthetic sockets with optimized fiber orientation to meet the load bearing and stiffness requirements. The three main topics for TUM-LCC include structural simulation and load path optimization, development of continuous carbon fiber additive manufacturing technology, and validation of the manufactured prosthetic sockets.
Acknowledgement
The chair thankfully acknowledges the funding for the project “AutoKOOP” provided by the German Federal Ministry of Education and Research (BMBF) under the funding scheme KMU-innovativ: Medizintechnik (Funding Code: 13GW0735).

Contact Persons
Chih-Yu Chen, M.Sc.; Dipl.-Ing. Thomas Wettemann
