Additive-Manufactured Prosthesis Covers for Custom Fit and Protection
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Solution Overview
Problem
Existing prosthesis covers are complex to manufacture, require high tool investment, and lack customization options, with conventional methods failing to achieve a natural appearance and adequate protection.
Innovation Solution
A prosthesis cover produced via additive manufacturing, featuring a flexible main body with structural elements applied on the outer side, allowing for customization through varied shapes, materials, and functions, such as improved adhesion using high surface energy materials and UV-hardened polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If prosthesis covers are produced from foam material using sanding or cut-off methods, then the main body can be adapted to patient contour, but the manufacturing process becomes complex and time-consuming requiring experienced orthopedic technicians
Solution Approach 1:
The patent replaces traditional mechanical sanding and cut-off methods with a 3D scanning system and computer-controlled additive manufacturing process. The scanning device captures patient limb geometry digitally, and the cover is produced automatically by a 3D printer based on digital models, eliminating the need for manual material removal by skilled technicians.
Solution Approach 2:
The invention changes the manufacturing approach from subtractive (removing material) to additive (depositing material layer by layer). This parameter change in the manufacturing process enables automatic production of custom-fitted covers without requiring manual intervention or extensive technician experience.
2Shape
If sanding operations are performed on foam material, then the main body can be shaped to fit the patient, but the surface becomes rough requiring additional fabric covering
Solution Approach 1:
The patent replaces mechanical sanding operations with a 3D scanning and additive manufacturing system. The scanning device captures the exact patient contour, and the 3D printer deposits material in controlled layers to achieve smooth, precise surfaces directly during manufacturing, eliminating the rough surfaces caused by sanding.
Solution Approach 2:
The invention performs the shaping action during the additive manufacturing process itself rather than as a subsequent finishing operation. The cover is formed with the correct smooth contour from the beginning through controlled material deposition, preventing the need for additional fabric coverings to hide rough surfaces.
3Manufacturing precision
If bowl-like prosthesis covers made of plastic, composite material or metal are used, then the outer side remains smooth, but the appearance becomes rather technical and less natural
Solution Approach 1:
The patent changes the material parameter from traditional smooth plastics or metals to foam materials that can be digitally shaped. The 3D scanning and additive manufacturing process enables these foam covers to achieve both smooth surfaces and natural, skin-like appearances through precise digital modeling and layer-by-layer construction.
Solution Approach 2:
The invention uses foam material as a base that can be combined with other materials or treatments to achieve both smoothness and natural appearance. The additive manufacturing process allows for creating composite structures with different surface properties in different regions of the same cover.
4Reliability
If conventional prosthesis covers are manufactured, then basic coverage is provided, but customization options are limited and tool investment is high
Solution Approach 1:
The patent replaces conventional manufacturing tooling with a 3D scanning and additive manufacturing system. This substitution eliminates the need for expensive custom molds and tools for each patient, as the 3D printer can automatically produce customized covers from digital models, making customization economically viable.
Solution Approach 2:
The invention changes the production mode from batch manufacturing with fixed tooling to on-demand additive manufacturing. This parameter change enables each cover to be customized to the specific patient's anatomy and preferences without requiring separate tooling investments, as the digital model can be easily modified and reprinted.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient, customizable production of prosthesis covers with enhanced protection, ventilation, haptics, and appearance, reducing tool costs and simplifying the manufacturing process.
Implementation Method 1
the material to be applied being a polymer which is hardened by UV irradiation
Data Source
AI summary
The invention relates to a prosthesis cover having at least one fastening device (20) for securing the prosthesis cover (1) to a prosthesis component (2), and a flexible main body (10) which has an inner side (11) facing the prosthesis component (2) in the applied state and an outer side (12) opposite the inner side (11), on which outer side the at least one fastening device (20) is arranged, wherein at least one structural element (30) protruding from the outer side (12) is applied to the outer side (12) in an additive manufacturing process.