Description:DESCRIPTION
TECHNICAL FIELD
[001] This disclosure relates generally to the field of medical devices, more particularly to an orthopedic device and a method of manufacturing thereof.
Background
[002] Orthopedic devices are medical tools or devices designed to treat or prevent musculoskeletal injuries or disorders owing to trauma, congenital conditions and degenerative diseases. The orthopedic devices may include internal fixation tools such as screws, washers, compression plates, and the like, and external fixation tools such as cervical collars, fixators, and the like. The external fixation tools are widely used for fracture fixation and may be implemented on an outer portion of the joint, neck, and the like for post-surgical recovery.
[003] Conventionally, orthopedic devices such as external fixation tools are typically made up of uniform foam, plastic, or a combination of both, which restricts the joint or neck movement entirely to ensure stabilization. Additionally, the orthopedic devices are bulky, uncomfortable to wear, and may not accommodate patient-specific motion needs. In some cases, some patients may need to restrict an upward motion while allowing downward motion, or vice versa, absence of which may result in slowing down of the post-surgical recovery, or the condition of the patient may become critical. Moreover, conventional orthopedic devices with uniform design may lead to reduced breathability in case of cervical collar, skin irritation especially when the skin of the patient is sensitive, discomfort when worn for extended periods, and the like.
[004] Accordingly, there is a necessity for an orthopedic device that is lightweight, ergonomically designed, adaptive, and capable of controlling bending motion of the injured body part of a user.
SUMMARY
[005] In an embodiment, an orthopedic device is disclosed. The orthopedic device may include an inner layer. The inner layer may include a plurality of zones, each zone may include a meta structure. The meta structure of each zone may be formed in a morphing transition with the meta structure of an adjacent zone to allow a predefined variation in a degree of movement across the plurality of zones.
[006] In another embodiment, a method of manufacturing an orthopedic device is disclosed. The method may include forming an inner layer. The inner layer may include a plurality of zones, each zone may include a meta structure. The meta structure of each zone may be formed in a morphing transition with the meta structure of the adjacent zone to allow a predefined variation in a degree of movement across the plurality of zones.
[007] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[008] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles.
[009] FIG. 1 illustrates a schematic of an orthopedic device, in accordance with an embodiment of the present disclosure.
[010] FIG. 2A illustrates a schematic of a first meta structure, in accordance with an embodiment of the present disclosure.
[011] FIG. 2B illustrates a schematic of the first meta structure in a compressed state, in accordance with an embodiment of the present disclosure
[012] FIG. 3 illustrates a schematic of a second meta structure, in accordance with an embodiment of the present disclosure.
[013] FIG. 4 illustrates a schematic of a third meta structure, in accordance with an embodiment of the present disclosure.
[014] FIG. 5 illustrates a flow chart of a method of manufacturing the orthopedic device, in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
[015] The foregoing description has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which forms the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying other devices, systems, assemblies, and mechanisms for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristics of the disclosure, to its device or system, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
[016] The terms “including”, “comprises”, “comprising”, “comprising of” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a system or a device that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device. In other words, one or more elements in a system or apparatus preceded by “comprises… a” do not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
[017] Reference will now be made to the exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. Wherever possible, the same numerals have been used to refer to the same or like parts. The following paragraphs describe the present disclosure with reference to FIGs. 1-5.
[018] As explained earlier, the orthopedic devices are used in the treatment, management, replacement, or correction of musculoskeletal injuries, such as including bones, joints, muscles, ligaments, tendons, and the like. Additionally, due to a uniform structure of the orthopedic devices, mild to moderate pressure is exerted on a body part from the plurality of body parts of the user to stabilize the joints or the bones by limiting the movement. Furthermore, as a result, skin irritation, impaired circulation at high pressure, muscle atrophy, discomfort and sweating, and the like may be experienced by the user.
[019] Thus, the present disclosure provides an orthopedic device with a controlled motion. The controlled motion allows the body part of user to move across a plurality of zones of the orthopedic device. By virtue of the controlled motion, the exerted pressure may be adjusted across the bones, the joints, the muscles, the ligaments, the tendons, and the like. Accordingly, the present disclosure provides an orthopedic device, and a method of manufacturing thereof is disclosed.
[020] Referring now to FIG. 1, a schematic 100 of an orthopedic device 102, in accordance with an exemplary embodiment of the present disclosure. FIG. 1 depicts a schematic 100 of a user 103 wearing the orthopedic device 102 around the neck. The user 103 may be suffering from an injury on the neck which requires stabilization thereof. By way of example, the orthopedic device 102 may include, but is not limited to, a support device, a brace, a cervical collar, an ankle support, a knee support, an elbow support, a wrist support, a neck support, a shoulder support and the like.
[021] The orthopedic device 102 may be customized based on the requirements of the user 103 such as an intensity of injury, an injured body part from a plurality of body parts, and the like. The orthopedic device 102 may be customized to move up or allow a predefined motion to a predefined variation based on the requirements of the user. For example, the predefined variation may include variation in a motion, such as a prohibited motion, a restricted motion, and the like, across the orthopedic device 102. The is explained in greater detail, hereinafter.
[022] In an embodiment, the orthopedic device 102 may include an inner layer which may be divided into a plurality of zones. Each zone may be configured to allow the predefined variation of a degree of movement in the injured body part (e.g., neck) based on the intensity of the injury. Further, each zone may allow the predefined motion, any motion, and the restricted motion to replicate the injured body part of the user. The predefined variation may be employed by a meta structure in corresponding zones of the orthopedic device 102. In an embodiment, the plurality of zones may include a first zone 104, a second zone 106, and a third zone 108. Each zone 104, 106, 108, may define the meta structure. Each zone may be formed using a polymer selected from group of materials selected from a group which may include, but not limited to thermoplastic polyurethane (TPU), thermoplastic elastomers (TPEs), thermoplastic copolyester (TPC), bio-based TPUs (BIO-TPUs), silicone, and other flexible polymers like polyvinyl chloride (PVC). As apparent in FIG. 1, the first zone 104 may be disposed with a front portion of the neck, the second zone 106 may be disposed with a side portion of the neck, and the third zone 108 may be disposed with a back portion of the neck.
[023] The meta structure may include an internal structure made up of repeating patterns or geometric unit cells. The meta structure may include, but are not limited to, auxetic, honeycomb, open lattice, soft mesh structures, and the like. By way of example, the meta structure of each zone may be formed in a morphing transition with the adjacent zones to allow the predefined variation in a degree of movement across the plurality of zones. For example, the meta structure of the first zone 104 may be formed in a morphing transition with the meta structure of the second zone 106, and the meta structure of zone 106 may be formed in a morphing transition of the third zone 108.
[024] The morphing transition may include a transition of a geometry, orientation, shape, and the like of a plurality of unit cells of each meta structure. Such transition may provide an ability to allow a gradual change from at least one meta structure to the adjacent meta structure. The morphing transition across the zones may cause a smooth transition in geometry of the meta structure, thus reducing stress concentrations and improving bonding strength of each meta structure.
[025] With continued reference to FIG. 1, the first zone 104 may include a first meta structure. Further, the first meta structure may exhibit a first degree of stiffness to allow a predefined motion across the first zone 104 of the orthopedic device 102. For example, the predefined motion is a relaxed motion for the injured body part. Further, the second zone 106 may include a second meta structure. The second meta structure may exhibit a second degree of stiffness to restrict motion across the second zone 106 of the orthopedic device 102. Furthermore, the third zone 108 may include a third meta structure. The third meta structure may exhibit a third degree of stiffness to prevent any motion across the third zone 108 of the orthopedic device 102.
[026] In an embodiment, the orthopedic device 102 may include an outer layer (not shown). The outer layer may be formed using skin-comforting soft textile material, such as but not limited to a soft foam, medical-grade silicon, viscoelastic polyurethane foam, neoprene, cotton terry cloth, microfiber fabric, Coolmax® fabric, Gel-infused liners or pads, plush velour, and the like. Further, the outer layer is configured to protect the inner layer of the orthopedic device 102 from external conditions. Additionally, the orthopedic device 102 may be formed of a single material on
each zone of the orthopedic device 102.
[027] To elaborate further, consider a scenario when the user 103 suffers an injury to the back portion of the neck. The back portion may be a plurality of posterior elements of at least one vertebra (e.g. fifth cervical vertebra) in the neck. The injury involved a stable fracture of the vertebra and a sprain of a ligamentum nuchae (the ligament at the back of the neck). Therefore, the user 103 is recommended to immobilize a bending motion of the back portion. Although the user 103 is allowed a bending motion in a forward direction (flexion) of the neck to prevent stiffness and encourage gentle mobility, if tolerated. Therefore, the orthopedic device 102 may be customized which involves the formation thereof using various meta structures in the corresponding zone of the orthopedic device 102. The formation is explained in conjunction with FIGs. 2A-4.
[028] Referring now to FIG. 2A, a schematic 200A of a first meta structure 202 is illustrated, in accordance with an embodiment of the present disclosure. And referring now to FIG. 2B, a schematic 200B of the first meta structure 202 in a compressed state is illustrated, in accordance with an embodiment of the present disclosure. FIGs. 2A-2B are explained in conjunction with FIG. 1.
[029] As apparent from FIG. 2A and as explained earlier, the first meta structure 202 may be implemented in the first zone 104 in order to allow the bending motion across the first zone 104 based on the intensity of the injured body part. Further, the predefined motion refers to a relaxed motion. The first meta structure 202 may include a honeycomb structure with the first degree of stiffness to allow a bending motion across the first zone 104. For example, a honeycomb structure may include, but is not limited to, auxetic structures such as re-entrant honeycombs, rectangular units, chiral structures, helical or spiral Lattices, Voronoi-based cellular structures, and the like.
[030] In an embodiment, the honeycomb meta structure may include a three-dimensional sequential arrangement of the plurality of unit cells. The honeycomb meta structure may include a type of honeycomb made up of a plurality of inward-pointing cell walls depicting an inward “re-entrant” or “bow-tie” orientation. The honeycomb meta structure may be formed by a plurality of inward-pointing cell walls, which may be configured to control bending across the front portion of the neck. The plurality of inward-pointing cell walls may provide an ability to exhibit a negative Poisson’s ratio, which may allow each inward-pointing cell wall to be expanded in a transverse direction when stretched and contracted when compressed. The negative Poisson’s ratio may be a tendency of the honeycomb meta structure to deform in a direction perpendicular to an applied force. By virtue of the honeycomb structure and the negative Poisson’s ratio, the first meta structure 202 may be compressed and/or expanded by the first degree of stiffness in the predefined motion across the first zone 104.
[031] As apparent from FIG. 2B, and by way of example, the first meta structure 202 may be subjected to the compressed state to respond to the bending motion of the neck. In the compressed state, a size of corresponding unit cells in the first meta structure 202 may be reduced. Additionally, by virtue of the negative Poisson’s ratio, the size of the plurality of unit cells corresponding to the front portion expand in the transverse direction when stretched or may contract in the transverse direction when compressed. Accordingly, the predefined motion may be allowed across the front portion of the neck.
[032] By way of example, in the scenario of injury to the back portion of the neck, the user 103 is allowed to bend the neck forward in the predefined motion. Hence, the first zone 104 is formed to allow the forward bending of the front portion of the neck up to the predefined variation by the first degree of stiffness. Such motion provides the comfort to the user 103 by allowing the user 103 to move the neck to-and-fro vertically against the first degree of stiffness due to the compression and expansion capabilities exhibited by the first meta structure 202.
[033] Referring now to FIG. 3, a schematic 300 of a second meta structure 302 is illustrated, in accordance with an embodiment of the present disclosure. FIG. 3 is explained in conjunction with FIGs. 1-2. In an embodiment, the second meta structure 302 may be implemented in the second zone 106. The second meta structure may include the second degree of stiffness which may be greater than the first degree of stiffness, thus the restricted motion across the second zone 106 may be allowed. The second meta structure 302 may include, but is not limited to an Open lattice structure, and the like. By way of example, the open lattice structure may be referred to as a Biomimetic structure, Bone-Inspired Dense Trabecular Structure, TPMS Structure (Closed, Dense Gyroid/Diamond), Cortical Bone-Mimicking Solid Shell, Shell-Based Architecture, coral-inspired structure, and the like.
[034] The open lattice structure may include a three-dimensional (3D) arrangement of the plurality of unit cells. The open lattice structure may include a plurality of connecting bars leaving voids within an overall framework of the second meta structure 302. Accordingly, the open lattice structure may be characterized by a high stiffness-to-weight ratio and strong energy absorption capabilities. Therefore, the second meta structure 302 may be tuned for multi-axial dimension and orientation transitions, which ensure the adaptability of the second meta structure 302 based on the shape and orientation of the injured body part. Therefore, the second meta structure 302 may allow the restricted motion of the side portion of the neck. The side portion may include a lateral motion and the bending motion by the second degree of stiffness.
[035] By way of example, the open lattice structure may be configured to enable the restricted motion of the side portion of the neck the user 103. The restricted motion may be neither excessively rigid nor excessively flexible, thereby allowing multi-axial motion across the side portion of the neck. It is to be noted that the restricted motion may be enabled by the second degree of stiffness of the open lattice structure, which is greater than the first degree of stiffness.
[036] By way of example and as apparent from FIG. 1, the back portion of the user 103 may be injured and the side portion of the user 103 may be formed adjacent to the back portion of the neck. Further, the second zone 106 may be disposed with the side portion. Further, the side portion may be moved due to a lower intensity of the injury thereof. It is to be noted that, when the side portion is moved, the back portion may remain unaffected. By virtue of the open lattice structure of the second meta structure 302, the side portion of the neck may be moved in a restricted motion. The restricted motion herein may include controlled motion of the neck in a transverse direction. The open lattice structure may provide less resistance to deformation from the bending motion or lateral motion of the side portion. Therefore, the open lattice structure may allow the restricted motion across the second zone 106.
[037] Referring now to FIG. 4, a schematic 400 of a third meta structure 402 is illustrated, in accordance with an embodiment of the present disclosure. FIG. 4 is explained in conjunction with FIGs. 1-3. In an embodiment, the third meta structure 402 may be implemented in the third zone 108. The third meta structure 402 may include the third degree of stiffness which may be greater than the second degree of stiffness, thus preventing any motion across the third zone 108. By way of example, the third meta structure 402 may include, but is not limited to, a stiff honeycomb structure with the third degree of stiffness greater than the second degree of stiffness to prevent any motion across the third zone 108.
[038] The stiff honeycomb structure may be formed by a three-dimensional (3D) arrangement of the plurality of unit cells, such as beam-based structures, lattice-based structures such as Octet truss, Diamond lattice, Solid Fill or graded solid structures, Auxetic structures, Triply Periodic Minimal Surfaces (TPMS), and the like. For example, the stiff honeycomb structure may include a plurality of hexagonal unit cell structures, each unit cell surrounded by six sequential unit cells with 120° angles therebetween. By virtue of such stiff honeycomb structure, any motion may be prevented such that the back portion of the neck is stabilized from any unintentional motion.
[039] By way of example, the back portion of the user 103 may be injured and required to be stabilized. Therefore, the third zone 108 may be disposed with the back portion. By virtue of the stiff honeycomb structure, the third meta structure 402 may provide maximum resistance to deformation from the bending motion of the back portion which may occur due to unintentional movement of the back portion. Therefore, the stiff honeycomb structure may be configured to tune the stiffness by adjusting wall thickness, angle, and orientation of each unit cell size in order to adjust the degree of stiffness. It is to be noted that the third zone 108 possesses higher rigidity relative to the second zone 106 to prevent undesirable motion and restrict any motion of the back portion of the neck. Thus, the neck support may be provided to the user.
[040] In an embodiment, referring to FIG. 5, which illustrates a flow chart 500 of a method of manufacturing the orthopedic device 102, in accordance with an embodiment of the present disclosure. At step 502, the inner layer may be formed. The inner layer may include a plurality of zones, and each zone may include the meta structure. Further, at step 504, the meta structure of each zone may be formed in the morphing transition with the meta structure of adjacent zones to allow a predefined variation in the degree of movement across the plurality of zones.
[041] The manufacturing of the orthopedic device 102 may include, but is not limited to, three-dimensional (3D) printing, casting, machining, forging, bioprinting, stereolithography (SLA), and the like. In an embodiment, the manufacturing of the orthopedic device 102 is done using the 3D printing process. The manufacturing process may include a plurality of steps, such as but not limited to identifying clinical needs (For example, knee replacement, neck bone maintenance or spinal implant), selecting an optimal material for manufacturing that is lightweight and easily adaptable to manufacture each of the meta structures of the orthopedic device 102.
[042] In order to manufacture the orthopedic device 102, a CAD (Computer-Aided-Design) modelling software may be used to create three-dimensional models. In an embodiment, the single material may be selected to manufacture the orthopedic device 102, such as but not limited to, Thermoplastic Polyurethane (TPU). The manufacturing process may further include prototyping using 3D printing or Additive manufacturing, which is often used for complex shapes or custom devices, or using any other best practice. Common existing 3D printing for orthopedic devices may include, but not be limited to, Fused Deposition Modelling (FDM) or Stereolithography (SLA) for polymers, and the like.
[043] As will be appreciated by those skilled in the art, the orthopedic device and method of manufacturing thereof described in various embodiments discussed above are not routine, or conventional or well understood in the art. The orthopedic device discussed above may be capable of offering several advantages.
[044] Firstly, the disclosed orthopedic device try to overcome the problem of the uniform structure of the prior devices, which does not adhere to the anatomy of the user. Secondly, the orthopedic device is configured to enhance comfort to the user by allowing a dynamic motion across the plurality of zones i.e., in the predefined motion, the restricted motion, and any motion corresponding to the injured body part. In other words, the orthopedic device may be implemented as a support device, a brace, a cervical collar, an ankle support, a knee support, an elbow support, a wrist support, a neck support, a shoulder support, and the like.
[045] Thirdly, the plurality of zones are customizable to restrict the motion based on the intensity of the injury. The proposed solution allows for precise control over neck movements, enabling or restricting motion in specific directions using meta structures, without utilizing any other equipment or device.
[046] Lastly, the meta structures provide a lightweight and breathable design that conforms to the anatomy of the user, potentially offering superior comfort. The design of the proposed orthopedic device is inherent, requiring no manual adjustments or mechanical parts, which simplifies usage and reduces the risk of mechanical failure. In this way, the proposed orthopedic device enhances comfort, provides passive functionality, and directional control to the user.
[047] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for the sake of clarity.
[048] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation, no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
[049] In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.
[050] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims. , Claims:CLAIMS
I/We Claim:
1. An orthopedic device (102) comprising:
an inner layer comprising a plurality of zones, each zone comprising a meta structure, wherein the meta structure of each zone is formed in a morphing transition with the meta structure of adjacent zones to allow a predefined variation in the degree of movement across the plurality of zones.
2. The orthopedic device (102) as claimed in claim 1, wherein the plurality of zones in the inner layer comprises at least one of:
a first zone (104) exhibiting a first degree of stiffness;
a second zone (106) exhibiting a second degree of stiffness; and
a third zone (108) exhibiting a third degree of stiffness.
3. The orthopedic device (102) as claimed in claim 2, wherein the first zone (104) comprises:
a first meta structure (202) with the first degree of stiffness to allow a predefined motion across the first zone (104) of the orthopedic device (102), wherein the first meta structure (202) comprises:
a honeycomb structure with the first degree of stiffness to allow a bending motion across the first zone (104).
4. The orthopedic device (102) as claimed in claim 2, wherein the second zone (106) comprises:
a second meta structure (302) with the second degree of stiffness greater than the first degree of stiffness to allow a restricted motion across the second zone (106) of the orthopaedic device (102), wherein the second meta structure (302) comprises:
an open lattice structure with the second degree of stiffness greater than the first degree of stiffness to allow the restricted motion across the second zone (106).
5. The orthopedic device (102) as claimed in claim 2, wherein the third zone (108) comprises:
a third meta structure (402) with the third degree of stiffness greater than the second degree of stiffness to prevent any motion across the third zone (108), wherein the third meta structure (402) comprises:
a stiff honeycomb structure with the third degree of stiffness greater than the second degree of stiffness to prevent any motion across the third zone (108).
6. The orthopedic device (102) as claimed in claim 1, wherein the plurality of zones is formed using a polymer selected from group of materials comprising thermoplastic polyurethane (TPU), thermoplastic elastomers (TPEs), thermoplastic copolyester (TPC), bio-based TPUs (BIO-TPUs), silicone, and other flexible polymers like polyvinyl chloride (PVC).
7. A method of manufacturing an orthopedic device (102), the method comprising:
forming an inner layer comprising a plurality of zones, each zone comprising a meta structure, wherein a meta structure of each zone is formed in a morphing transition with the meta structure of adjacent zones to allow a predefined variation in the degree of movement across the plurality of zones.
8. The method as claimed in claim 7, wherein the plurality of zones in the inner layer comprises at least one of:
a first zone (104) exhibiting a first degree of stiffness;
a second zone (106) exhibiting a second degree of stiffness; and
a third zone (108) exhibiting a third degree of stiffness.
9. The method as claimed in claim 8, wherein the first zone (104) comprises:
a first meta structure (202) with the first degree of stiffness to allow a predefined motion across the first zone (104) of the orthopedic device (102), wherein the first meta structure (202) comprises:
a honeycomb structure with the first degree of stiffness to allow a bending motion across the first zone (104).
10. The method as claimed in claim 8, wherein the second zone (106) comprises:
a second meta structure (302) with the second degree of stiffness greater than the first degree of stiffness to allow a restricted motion across the second zone (106) of the orthopedic device (102), wherein the second meta structure (302) comprises:
an open lattice structure with the second degree of stiffness greater than the first degree of stiffness to allow the restricted motion across the second zone (106).
11. The method as claimed in claim 8, wherein the third zone (108) comprises:
a third meta structure (402) with the third degree of stiffness greater than the second degree of stiffness to prevent any motion across the third zone (108), wherein the third meta structure (402) comprises:
a stiff honeycomb structure with the third degree of stiffness greater than the second degree of stiffness to prevent any motion across the third zone (108).
12. The method as claimed in claim 7, wherein the plurality of zones is formed using a polymer selected from group of materials comprising thermoplastic polyurethane (TPU), thermoplastic elastomers (TPEs), thermoplastic copolyester (TPC), bio-based TPUs (BIO-TPUs), silicone, and other flexible polymers like polyvinyl chloride (PVC).