传统工艺如石膏制作的足踝矫形器存在气密性低、制作效率低、舒适度差等缺点。针对此问题，文章采用逆向工程结合3D打印技术对踝足矫形器进行定制式设计，获取足部STL数据，联合逆向建模软件Geomagic studio与Rodin 4D对矫形器关键部位修型，用Grasshopper进行轻量化设计，降低打印成本与质量，通过有限元分析验证其力学性能，使用聚乳酸通过FDM 3D打印技术打印实物，并进行穿戴测试。结果表明：重建后模型精度最大偏差为0.868 mm，标准偏差0.047 1 mm，模型构造精准。镂空后的矫形器在30 N碰撞集中载荷下，2 mm厚度矫形器晶格中部峰值应力为16.32 MPa，最大变形1.49 mm，晶格右侧峰值应力为15.64 MPa，最大变形0.78 mm，峰值应力均小于PLA材料抗拉强度，最大变形均小于产品本身厚度2 mm，力学强度性能符合后续生产设计要求，实物穿戴测试表明产品舒适度较好。

The traditional process of foot and ankle orthoses made of gypsum has the disadvantages of low air tightness, low production efficiency and poor comfort. In order to solve this problem, this paper uses reverse engineering combined with 3D printing technology to customize the design of the ankle foot orthosis, obtains the foot STL data, combines the reverse modeling software Geomagic studio and Rodin 4D to modify the key parts of the orthosis, uses Grasshopper to carry out lightweight design, reduces the printing cost and quality, verifies its mechanical properties through finite element analysis, uses polylactic acid to print the physical object by FDM 3D printing technology, and conducts wear tests. The results show that the maximum deviation of the model accuracy after reconstruction is 0.868 mm, and the standard deviation is 0.047 1 mm, and the model structure is accurate. Under the concentrated load of 30 N collision, the peak stress in the middle of the 2 mm thickness orthosis is 16.32 MPa, the maximum deformation is 1.49 mm, the peak stress on the right side of the lattice is 15.64 MPa, the maximum deformation is 0.78 mm, the peak stress is less than the tensile strength of PLA material, the maximum deformation is less than the thickness of the product itself by 2 mm, the mechanical strength performance meets the requirements of subsequent production design, and the physical wear test shows that the product comfort is good.