Short answer

When designing orthotic devices, use a structured approach combining multicriteria decision-making with simulation to select materials like PLA and optimize for performance and efficiency.

Field: Final Production
Source: Processes (2025)
Method: Multicriteria Decision-Making (MCDM) and Finite Element Analysis (FEA) simulation.
Evidence: Strong effect

Multicriteria decision-making methods and simulation identified PLA as the most suitable material for orthotic splints, with a minimum thickness of 4mm required for structural integrity. This final production research insight is drawn from a 2025 study published in Processes. Using Multicriteria decision-making (mcdm) and finite element analysis (fea) simulation., researchers explored how this design variable affects real-world outcomes. The key design takeaway: When designing orthotic devices, use a structured approach combining multicriteria decision-making with simulation to select materials like PLA and optimize for performance and efficiency.

Study

Final ProductionNew This WeekStrong effect

PLA emerges as optimal material for low-energy fracture orthoses, requiring 4mm thickness

Multicriteria decision-making methods and simulation identified PLA as the most suitable material for orthotic splints, with a minimum thickness of 4mm required for structural integrity.

Processes · 2025

Key Findings

01PLA was consistently identified as the most suitable material for orthotic splints across three different MCDM methods.
02A minimum thickness of 4mm for a PLA orthosis was determined to be sufficient for acceptable stresses and deformations during wrist movements.
03Topological optimization reduced the mass of the preliminary PLA orthosis design by 9.58% while maintaining structural integrity.

Application

Design takeaway

When designing orthotic devices, use a structured approach combining multicriteria decision-making with simulation to select materials like PLA and optimize for performance and efficiency.

How to apply

When selecting materials for load-bearing or protective devices, use a weighted scoring system based on critical performance factors (e.g., strength-to-weight ratio, cost, manufacturability) and validate the chosen material's performance through simulation under expected load conditions.

Project actions

01When choosing materials for your design project, think about more than just one factor. Consider strength, weight, cost, and how easy it is to make.
02Use software to test how your material choice will perform under stress before you build anything.

Method & Evidence

AimTo identify the most suitable material for orthotic splints for low-energy bone fractures and determine its optimal thickness using simulation and multicriteria decision-making methods.

MethodMulticriteria Decision-Making (MCDM) and Finite Element Analysis (FEA) simulation.

ProcedureMaterials with mechanical properties similar to plaster were identified using Ansys CES Edupack. Three MCDM methods (TOPSIS, VIKOR, COPRAS) were applied to evaluate these materials based on strength, flexibility, weight, cost, and ease of manufacturing. PLA was selected as the optimal material. FEA simulations were then used to determine the minimum required thickness (4mm) for a PLA orthosis under simulated wrist movements. Topological optimization was also performed to reduce mass.

ContextMedical device design, specifically orthotics for fracture immobilization.

Variables

IVMaterial properties (strength, flexibility, weight, cost, ease of manufacturing).

DVSuitability score for orthotic splints, required material thickness, mass reduction.

CVMechanical properties of plaster as a benchmark, simulation parameters for wrist movements, software used (Ansys CES Edupack).

Strengths & Limitations

Strengths

+Employs multiple MCDM methods for robust consensus.
+Integrates material selection with structural simulation and optimization.

Limitations

The simulation might not perfectly replicate real-world forces, and the chosen material's long-term effects or user comfort might need further investigation.

Reliability & validity

The use of multiple MCDM methods increases the reliability of the material selection. Validity is supported by simulation of structural performance under defined loads.

Think critically

How might the 'ease of manufacturing' criterion influence material selection for a 3D-printed orthosis versus a traditionally molded one?

Design Principles

"Integrate quantitative decision-making frameworks and performance simulations early in the design process to rigorously select and validate materials and structural parameters."

This research provides a data-driven approach to material selection for medical devices, moving beyond traditional materials to explore advanced options. By integrating simulation and decision-making frameworks, designers can ensure functional performance, comfort, and efficient material usage in their designs.

What This Means for Your Design

Researchers used computer tools to pick the best plastic (PLA) for a brace that supports broken bones, finding it needs to be 4mm thick and can be made lighter.

How to use in your project

1.Reference this study when justifying your material selection process, especially if you use a decision matrix or simulation to support your choice.

Add to My Project

Quick Cite

Paragraph starter

This research demonstrates a systematic approach to material selection for orthotic devices, utilizing multicriteria decision-making methods and simulation to identify PLA as an optimal material requiring a 4mm thickness. This methodology, balancing mechanical properties, cost, and manufacturability, offers a robust framework for selecting materials in design projects where performance and efficiency are critical.

Source

Processes

Material Selection for the Development of Orthoses Using Multicriteria Methods (MCDMs) and Simulation

journal · 2025

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Questions About This Research

What does the research say about pla emerges as optimal material for low-energy fracture orthoses, requiring 4mm thickness?: When designing orthotic devices, use a structured approach combining multicriteria decision-making with simulation to select materials like PLA and optimize for performance and efficiency. Evidence: Processes (2025).
Why does "PLA emerges as optimal material for low-energy fracture orthoses, requiring 4mm thickness" matter for design?: This research provides a data-driven approach to material selection for medical devices, moving beyond traditional materials to explore advanced options. By integrating simulation and decision-making frameworks, designers can ensure functional performance, comfort, and efficient material usage in their designs.
How can designers apply this research?: When designing orthotic devices, use a structured approach combining multicriteria decision-making with simulation to select materials like PLA and optimize for performance and efficiency.
What were the main findings?: PLA was consistently identified as the most suitable material for orthotic splints across three different MCDM methods.. A minimum thickness of 4mm for a PLA orthosis was determined to be sufficient for acceptable stresses and deformations during wrist movements.. Topological optimization reduced the mass of the preliminary PLA orthosis design by 9.58% while maintaining structural integrity.
What research method was used?: Multicriteria Decision-Making (MCDM) and Finite Element Analysis (FEA) simulation..
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2025 journal from Processes.
What should I do differently in my next project?: When selecting materials for load-bearing or protective devices, use a weighted scoring system based on critical performance factors (e.g., strength-to-weight ratio, cost, manufacturability) and validate the chosen material's performance through simulation under expected load conditions.
What are the limitations?: The study focused on specific mechanical properties and did not extensively explore long-term durability, biocompatibility, or patient-specific variations in fracture types or anatomy. The simulation was based on four primary wrist movements, which may not encompass all potential stress scenarios.