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Additive manufacturing, especially fused deposition modelling, enhances these benefits by providing faster, more precise, and more comfortable orthoses. The present study evaluates nine polymeric materials printed in horizontal and vertical directions by assessing their performance through compressive, flexural, and tensile tests. Among all materials, polycarbonate, polylactic acid, and ULTEMTM 1010 showed the most promising results, not only because they had the highest mechanical values, but also due to their minimal or no difference in performance between printing directions, making them advantageous in orthoses fabrication. Based on this, a finite element model of an ankle\u2013foot orthosis was developed to simulate the deformation, strain, and stress fields under static conditions. The findings aim to optimize material selection for orthotic fabrication, where ULTEMTM 1010 is presented as the material with improved performance and durability.<\/jats:p>","DOI":"10.3390\/polym16182553","type":"journal-article","created":{"date-parts":[[2024,9,10]],"date-time":"2024-09-10T04:35:24Z","timestamp":1725942924000},"page":"2553","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":8,"title":["Material Performance Evaluation for Customized Orthoses: Compression, Flexural, and Tensile Tests Combined with Finite Element Analysis"],"prefix":"10.3390","volume":"16","author":[{"ORCID":"https:\/\/orcid.org\/0000-0003-3621-7095","authenticated-orcid":false,"given":"Daniela","family":"Trindade","sequence":"first","affiliation":[{"name":"Center for Rapid and Sustainable Product Development (CDRSP), Polytechnic of Leiria, 2430-028 Marinha Grande, Portugal"},{"name":"Applied Research Institute, Polytechnic Institute of Coimbra, Rua da Miseric\u00f3rdia, Lagar dos Corti\u00e7os, S. Martinho do Bispo, 3045-093 Coimbra, Portugal"},{"name":"Abel Salazar Biomedical Sciences Institute (ICBAS), University of Porto (UP), Rua de Jorge Viterbo Ferreira, No. 228, 4050-313 Porto, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0009-0000-7656-8960","authenticated-orcid":false,"given":"Rachel","family":"Habiba","sequence":"additional","affiliation":[{"name":"Center for Rapid and Sustainable Product Development (CDRSP), Polytechnic of Leiria, 2430-028 Marinha Grande, Portugal"},{"name":"Department of Mechanical Engineering, University of Coimbra, Rua Luis Reis Santos, 3030-788 Coimbra, Portugal"}]},{"given":"Cristiana","family":"Fernandes","sequence":"additional","affiliation":[{"name":"Center for Rapid and Sustainable Product Development (CDRSP), Polytechnic of Leiria, 2430-028 Marinha Grande, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-4280-6590","authenticated-orcid":false,"given":"Andr\u00e9 A.","family":"Costa","sequence":"additional","affiliation":[{"name":"Center for Rapid and Sustainable Product Development (CDRSP), Polytechnic of Leiria, 2430-028 Marinha Grande, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-3931-8206","authenticated-orcid":false,"given":"Rui","family":"Silva","sequence":"additional","affiliation":[{"name":"Center for Rapid and Sustainable Product Development (CDRSP), Polytechnic of Leiria, 2430-028 Marinha Grande, Portugal"},{"name":"CIPER, Faculdade de Motricidade Humana, Universidade de Lisboa, 1495 Cruz Quebrada Dafundo, 1649-004 Lisbon, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-5016-0868","authenticated-orcid":false,"given":"Nuno","family":"Alves","sequence":"additional","affiliation":[{"name":"Center for Rapid and Sustainable Product Development (CDRSP), Polytechnic of Leiria, 2430-028 Marinha Grande, Portugal"},{"name":"Associate Laboratory for Advanced Production and Intelligent Systems (ARISE), 4050-313 Porto, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-8155-0079","authenticated-orcid":false,"given":"Rui","family":"Martins","sequence":"additional","affiliation":[{"name":"UNIDEMI, Department of Mechanical and Industrial Engineering, Nova School of Science and Technology, Universidade NOVA de Lisboa, Campus de Caparica, 2829-516 Caparica, Portugal"},{"name":"Laborat\u00f3rio Associado de Sistemas Inteligentes (LASI), 4800-058 Guimar\u00e3es, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-0012-4380","authenticated-orcid":false,"given":"C\u00e2ndida","family":"Mal\u00e7a","sequence":"additional","affiliation":[{"name":"Center for Rapid and Sustainable Product Development (CDRSP), Polytechnic of Leiria, 2430-028 Marinha Grande, Portugal"},{"name":"Coimbra Institute of Engineering (ISEC), Polytechnic Institute of Coimbra, Rua Pedro Nunes, Quinta da Nora, 3030-199 Coimbra, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-2471-1125","authenticated-orcid":false,"given":"Ricardo","family":"Branco","sequence":"additional","affiliation":[{"name":"CEMMPRE-ARISE, Department of Mechanical Engineering, University of Coimbra, Rua Luis Reis Santos, 3030-788 Coimbra, Portugal"}]},{"given":"Carla","family":"Moura","sequence":"additional","affiliation":[{"name":"Center for Rapid and Sustainable Product Development (CDRSP), Polytechnic of Leiria, 2430-028 Marinha Grande, Portugal"},{"name":"Applied Research Institute, Polytechnic Institute of Coimbra, Rua da Miseric\u00f3rdia, Lagar dos Corti\u00e7os, S. Martinho do Bispo, 3045-093 Coimbra, Portugal"},{"name":"Research Centre for Natural Resources Environment and Society (CERNAS), Polytechnic Institute of Coimbra, Bencanta, 3045-601 Coimbra, Portugal"}]}],"member":"1968","published-online":{"date-parts":[[2024,9,10]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"85","DOI":"10.1007\/s40964-019-00104-7","article-title":"A Review on the Use of Additive Manufacturing to Produce Lower Limb Orthoses","volume":"5","author":"Alqahtani","year":"2020","journal-title":"Prog. Addit. Manuf."},{"key":"ref_2","doi-asserted-by":"crossref","first-page":"141","DOI":"10.31686\/ijier.vol6.iss10.1175","article-title":"Additive Manufacturing of Customized Lower Limb Orthoses\u2014A Review","volume":"6","author":"Hensen","year":"2018","journal-title":"Int. J. Innov. Educ. 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