Modeling and Strength Calculations of Parts Made Using 3D Printing Technology and Mounted in a Custom-Made Lower Limb Exoskeleton

This study is focused on the application of 3D-printed elements and conventional elements to create a prototype of a custom-made exoskeleton for lower limb rehabilitation. The 3D-printed elements were produced by using Fused Deposition Modeling technology and acrylonitrile butadiene styrene (ABS) material. The scope of this work involved the design and construction of an exoskeleton, experimental testing of the ABS material and numerical research by using the finite element method. On the basis of the obtained results, it was possible to deduce whether the load-bearing 3D-printed elements can be used in the proposed mechanical construction. The work contains full data of the material models used in FEM modeling, taking into account the orthotropic properties of the ABS material. Various types of finite elements were used in the presented FE models. The work is a comprehensive combination of material testing issues with the possibility of implementing the obtained results in numerical strength models of machine parts.