INTRODUCTION: According to Burkett (2012): "[...] connectivity is critical to the effective operation of the assistive device" for athletes in Paralympic winter sports. Further, the author concludes, "[...] the key issue is matching the residual function of the person with the assistive equipment". In sit-skiing, the connection between athlete and the assistive device (sit-ski) is a seat shell. Material fatigue of the seat led to the necessity of an exact replication. Three replication attempts were performed using the standard procedure of thermoforming. However, according to the athlete, the results did not deliver a seat with the same response characteristics; also, the handling performance compared to the original seat was not satisfactory. The aim of this proof of concept was to deliver an exact replication of the original seat by implementing a digital process chain of 3D-scanning and 3D-printing. After a successful seat replication, the next step was to customize a new seat based on the athlete`s body form using the same digital technology and process chain. Here, body shape 3D-data were obtained from scanning the athlete`s vacuum imprint in a sitting position on the sit-ski frame. METHODS: The original seat was digitally recorded using a 3D-Scanner (Artec Eva, LUX), data processing of the scan was performed using the software Artec Studio, 3D-analysis between seats was realized by using the software of Geomagic Control (Artec 3D, LUX), and for treatment of 3D-Data the softwares of Geomagic Wrap (Artec 3D, LUX) & Soildworks (GER) were used. 3D-Printing used the additive FFF-procedure (dddrop Leader, NED) and the final result received carbon lamination. Performance on snow in SL and GS was assessed by the athlete`s subjective rating using semantic differential and paired comparison methods. For scanning the body form, three vacuum pads were used (Mc Lean, GER). RESULTS: The digital process chain was able to deliver an exact replication of the old seat. A digital version was stored at the orthopedic technician so seats with a correct fit can be reproduced on demand. In addition, the method proved suitable to produce a seat based on the athlete`s body shape. DISCUSSION/CONCLUSION: The new procedural method was superior to the traditional method of thermoforming. A transfer of the method might be of interest for any sport using a seat as connection between athletes and their equipment.
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