Mechanical performance of 3D printed prosthetic sockets: an experimental and numerical study

A lower-limb socket is an integral part of a prosthesis with functions to connect the residual limb and transfer the loads to the prosthesis. As a result of long and costly traditional manufacturing methods, assessing the mechanical performance of such products is challenging. With additive manufacturing gaining ground in healthcare and rehabilitation, it is even more important for such products to be analyzed to ensure that they comply with the required safety regulations. In this study, sockets were 3D printed employing PLA from two different manufacturers, and mechanically tested to assess their ultimate strength. Results of finite-element analysis (FEA) informed their redesigns that were created reinforcing the sockets at the stress-concentration areas for improved mechanical performance. It was shown that FEA can assist the development of designs with improved performance. The material choice was found to have the strongest effect; hence, serious considerations need to be taken when selecting the material, especially for healthcare applications, to maintain high safety standards.