Optimization of the Impact Attenuation Capability of Three-Dimensional Printed Hip Protector Produced by Fused Deposition Modeling Using Response Surface Methodology

Fused deposition modeling has provided a cheap and effective method for the rapid production of prototypes and functional products in many spheres of life. In this study, three-dimensional (3D) printing techniques to produce and optimize a hip protector that will assure clinical efficacy are presented. The I-Optimal design was used to optimize the hip protector's significant parameters (infill density, shell thickness, and material shore hardness) to obtain maximum femoral neck force attenuation of the 3D-printed hip protector. A drop impact tower device simulates the impact force at the hip's parasagittal plane during a fall. The results show that the infill density has the most significant influence on attenuation properties, followed by the infill density combined with the material shore hardness. By maximizing all the parameters, it is demonstrated that using an additive manufacturing technique to print hip protectors could be an effective strategy in curbing hip fractures.