Digital Prosthetic Socket Fabrication via 3D Scanning
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Solution Overview
Problem
Current methods for crafting prosthetic sockets are inefficient, often leading to poorly fitting prosthetics that cause skin breakdown in amputees, due to the time-consuming and labor-intensive nature of traditional hand-casting techniques, and a shortage of skilled prosthetists.
Innovation Solution
A digital process using 3D scanning and software to create a modified mold of a residual limb, followed by fabrication with a 3D printer to produce a prosthetic limb from strong materials like ULTEM or carbon fiber, allowing for precise alignment and attachment design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional hand-casting techniques are used to fabricate prosthetic sockets, then the process allows for manual adjustment and customization, but the procedure is time-consuming and labor-intensive, leading to reduced productivity and increased cost
Solution Approach 1:
The patent uses 3D scanning to create a digital copy of the residual limb, replacing the traditional physical hand-casting process. This digital model can be manipulated and adjusted virtually, maintaining customization capabilities while eliminating the time-consuming nature of manual plaster casting and physical model modification.
Solution Approach 2:
The patent replaces the mechanical hand-casting process with computer-aided design (CAD) software and 3D printing technology. The digital workflow allows for rapid iteration and adjustment of socket design without requiring manual manipulation of physical materials, significantly reducing fabrication time while maintaining design flexibility.
2Manufacturing precision
If traditional hand-casting methods are employed, then prosthetists can manually refine socket fit, but the shortage of skilled prosthetists and their limited time results in poorly fitting prosthetics and skin breakdown
Solution Approach 1:
The patent incorporates pressure mapping technology and digital feedback mechanisms that provide real-time information about socket-limb interface pressures. This allows for precise identification and correction of pressure points during the design phase, ensuring optimal fit without requiring extensive manual trial-and-error adjustments by the prosthetist.
Solution Approach 2:
The patent performs preliminary digital adjustments and simulations of socket fit before actual fabrication. The CAD software allows the prosthetist to pre-adjust the digital model based on predicted pressure distribution and anatomical considerations, reducing the need for time-consuming post-fabrication modifications and multiple fitting sessions.
3Reliability
If multiple trial sockets are fabricated using traditional methods, then alignment and fit can be optimized, but the process requires extensive material waste and repeated manual fabrication cycles
Solution Approach 1:
The patent creates multiple virtual iterations of the socket design in the digital domain rather than physically fabricating multiple trial sockets. The CAD software allows for rapid modification and comparison of different design options, enabling optimization of fit and alignment without consuming additional materials for each iteration.
Solution Approach 2:
The patent performs preliminary digital validation and simulation of multiple socket designs before committing to physical fabrication. This allows the prosthetist to identify and correct potential fit issues in the virtual model, ensuring that only the optimized design is manufactured, thereby eliminating material waste from failed or rejected trial sockets.
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
This method significantly improves the efficiency and quality of prosthetic socket fitting, reducing the risk of skin breakdown and enabling faster, more accurate production of prosthetic limbs with precise alignment and attachment options.
Implementation Method 1
sending it to a 3D printer, which in turn has the ability to print out a completed, wearable prosthetic limb
Data Source
AI summary
A prosthetic limb and process to digitally construct a prosthetic limb which includes first, digitally producing a modified mold of a residual limb via 3d scanners and software; constructing a test socket from the digitally modified mold and be equipped with an alignable system; accurately scanning the test socket, along with finalized alignment that has been recorded and adjusted by a certified practitioner to provide a 3-D Image of the finalized prosthetic alignment; transferring the finalized digital alignment of the test socket to the finalized digitally modified mold; once the modified model has received the transferred alignment, fabricating the type of hookup in the socket; i.e., plug fit, four hole, support drop lock, or any other type of industry standard connection or accommodation via basic 3D software; and once the desired prosthetic attachment is finalized, sending finished file to a 3-D printer to produce the definitive prosthetic device.