AM lower-limb prosthetic socket: Using FEA for improved mechanical performance

Prosthetic sockets are bespoke products tailored to the needs of the individual user. Their manufacturing requires many workhours to achieve high quality and comfort. As modern technologies are introduced in healthcare, 3D printing of prosthetic sockets is also gaining ground. Still, prosthetic products made with this manufacturing process are limited and their mechanical performance is mostly unexplored. In this study, prosthetic sockets were 3D printed with PLA, using commercially available filament and printer. The sockets were tested in accordance with BS EN ISO 10328–2006 test instructions for ultimate strength to evaluate their ability to safely bear the loads caused by user's weight and movement. It was found that inconsistent behaviour occurs in materials and caution is advised when choosing them. Still, 3D printed sockets could sustain the required loads and, in some cases, exceed 5000 N (>5fold user's weight). Improved mechanical performance was achieved with a new socket design created utilising the data from finite-element analysis (FEA). The study addresses the challenges of using FEA to develop a 3D printed prosthetic socket and the benefits of the novel process for the healthcare industry.