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Home Postscript

Development of Heel Cushions for the IDEO

by Julia Marielle Castrucci
October 1, 2024
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The Intrepid Dynamic Exoskeletal Orthosis (IDEO) aids in the return to high function after severe lower-limb injuries. Its design incorporates a carbon fiber footplate, a dynamic posterior strut, and a proximal cuff that work to transfer energy around the foot/ankle/lower limb during gait. The IDEO’s design ensures that the ankle and midfoot are maintained in a comfortable, weight bearing position, enabling users to engage in their activities (including running) without discomfort. The IDEO reduces peak pressures on the forefoot by up to 60 percent, allowing active and retired servicemembers to resume high-level activities after limb salvage operations. The IDEO heel wedge is crucial for improving rollover characteristics by adjusting the footplate, strut stiffness, and heel cushions.

A key component to IDEO treatment success is tuning heel cushion stiffness to manage the transition from swing to stance. This has traditionally been done with Kingsley foam, but the production of this foam has been discontinued. To address the pressing need to find a replacement, my colleagues and I evaluated different types of FlexFoam for stiffness and durability.

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