Structural mechanical simulation to optimize the sensor arm geometry to be implemented on cranial remodeling orthosis

For the treatment of moderate and severe cases of deformational plagiocephaly, an asymmetrical deformation of the skull, a cranial remodeling orthosis (CRO) is used. For the development of a new CRO concept, a pressure sensor grid is placed inside the orthosis that will allow the monitoring of excessive pressures and incorrect CRO positioning throughout the treatment. To implement the sensor grid in the CRO, high mobility of the sensor arms structure that joins the several sensors of this grid is required, however, it is intended that this procedure does not damage the printed copper tracks on the sensor structure. In this study, computer simulations were performed to optimize the sensor arm structure geometry, minimizing undesirable mechanical behavior in the sensor structure when subjected to tensile forces and displacements applied during its placement in the CRO. It was observed that the different sensor arm structures geometries have different effects on the mechanical behavior of the sensor structure when subjected to tensile forces and tensile displacement. The zigzag curve geometry presents the best performance based on high mobility without intense strain on the structure that could damage the printed copper tracks.