National Winner of the 2021 James Dyson Award

LUNA AFO is an Ankle Foot Orthosis that grows with you.

The Problem

The LUNA Modular AFO is a new approach to Ankle Foot Orthosis design, targeted at young and growing individuals with Hereditary Spastic Paraplegia (HSP). HSP is a degenerative disease that causes impairments in the individual’s lower limbs. Currently, there are no treatments or cures which stop or reverse the condition and many resorts to assistive devices like Ankle Foot Orthoses (AFO). People still growing, especially children, often use rigid thermoplastic AFOs, which are purposely tight-fitting to provide optimal support but do not account for growing users resulting in bruises, cuts, and blisters.

How It Works

The LUNA AFO consists of two systems; a user-customised component called the LUNA Surface and a mass-manufactured component called the LUNA Module. The LUNA Module acts as the base to which the LUNA Surfaces are attached, prolonging use over several years rather than the 6-8 months found in traditional AFOs. When the LUNA AFO is deemed too small, the new Surfaces will replace the existing ones. The LUNA Surfaces are 3D printed parts designed to be form-fitted to each unique user. The parts use 3D printing and scanning technology to digitised the fabrication process, which currently involved complex moulding and casting techniques. The digitisation of this process reduces the number of tacit skills required from fabricators and results in more consistently accurate orthoses. The Surfaces are printed in Nylon 11, a semi-flexible bioplastic; the design manipulates this material to soften sensitive areas and visually indicates when parts are too small.

Step 1.

Set up a new LUNA AFO with customised LUNA Surface Plates.
Step 2.

When the Shapechange Feature indicates the LUNA Surfaces are too small. Its time for replacements.
Step 3.

The user’s legs are 3D scanned and new LUNA surfaces are custom 3D printed for each user.
Step 4.

Customised LUNA Surfaces are 3D printed and sent to the user.
Step 5.

Using a toolless system the old surfaces are replaced for the new ones and the cycle restarts.