3D Prosthetic Socket Alignment Transfer for Faster Replacement
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Solution Overview
Problem
The existing methods for manufacturing lower limb prostheses are time-consuming and require repeated alignment procedures due to changes in amputation stump volume or mobility, and there is no efficient way to transfer digitally determined alignment to a physical prosthesis.
Innovation Solution
A method involving 3D-data capture of a prior socket's inner surface and orientation, creation of a 3D model with an attachment area, determination of an orientation transmitter, and connection of the new socket to a component adapter using the transmitter to maintain the correct alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a new socket is manufactured to replace a prior socket, then the prosthesis can be renewed or adapted to changes in the amputation stump, but the alignment procedure must be redone from scratch which is time-consuming and uncomfortable for the wearer
Solution Approach 1:
The patent applies preliminary action by creating a digital 3D model of the prior socket including its alignment information before the new socket is manufactured. This digital model serves as a template that guides the manufacturing of the new socket with pre-determined alignment, eliminating the need to redo the alignment procedure from scratch.
Solution Approach 2:
The patent uses copying by creating a digital replica of the prior socket's geometry and alignment characteristics. The 3D scanning process captures the exact shape and orientation of the old socket, and this digital copy is used to manufacture the new socket with identical alignment properties, thus transferring the alignment information without physical realignment.
2Adaptability or versatility
If the socket is replaced due to wear or changes in amputation stump volume, then the prosthesis can continue to function, but the careful alignment achieved with the prior socket is lost and must be重新established through iterative adjustments
Solution Approach 1:
The patent replaces the mechanical alignment system with a digital one. Instead of physically adjusting the new socket through iterative mechanical procedures, the alignment is determined through 3D scanning and digital modeling. The digital model contains the alignment information that is directly transferred to the new socket manufacturing process, substituting manual mechanical adjustment with automated digital guidance.
Solution Approach 2:
The alignment configuration is performed in advance during the digital modeling phase before the new socket is manufactured. The 3D model captures the optimal alignment relative to other prosthetic components, and this pre-determined alignment is embedded in the manufacturing instructions for the new socket, eliminating the need for post-manufacturing adjustments.
3Manufacturing precision
If a check socket is modified to fit the patient, then the best fit can be achieved, but the modifications and alignment must be captured and transferred to the definitive socket instead of redoning the entire alignment procedure
Solution Approach 1:
The patent uses copying to capture the modifications made to the check socket. By 3D scanning the modified check socket, the exact geometry and alignment adjustments are copied into a digital model. This digital copy preserves all the fit optimizations made during the check socket phase, which can then be directly used to manufacture the definitive socket with the same precise fit.
4Extent of automation
If existing software tools are used to perform virtual bench alignment, then the alignment can be determined digitally, but it is not possible to transfer the digitally determined alignment to a physical prosthesis
Solution Approach 1:
The patent replaces the gap between digital and physical alignment systems by integrating 3D scanning and digital modeling directly into the manufacturing process. The digitally determined alignment from virtual bench alignment is transferred to the physical prosthesis through additive manufacturing or other manufacturing methods that use the digital model as direct guidance, eliminating the need to manually reproduce the digital alignment in the physical domain.
Data Source
AI summary
The Invention refers to a method for manufacturing a new prosthesis for a lower limb, the method comprising the following steps:a) Providing 3D-data of a prior inner surface of a prior socket and of ist position and its orientation relative to a component adapter, —b) Creating a 3D model of a prosthetic socket with an attachment area for a socket adapter, wherein the prosthetic socket has an inner surface based on the scanned prior inner surface and an outer surface, —c) Determining information about an orientation transmitter, —d) Manufacturing of the prosthetic socket based on the 3D model and providing the orientation transmitter based on the information, —e) Directly or indirectly connecting the manufactured socket to a component adapter by means of the orientation transmitter so that the position and orientation of the inner surface of the prosthetic socket relative to the position and orientation of the component adapter corresponds to the position and orientation of the prior inner surface of the prior socket to the component adapter.