Hinged Residual Limb Shell With Variable Thickness Fit
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Solution Overview
Problem
Conventional prosthetic and orthotic devices often fail to provide a comfortable and secure fit for post-operative residual limbs, as they do not account for the unique anatomical structure and varying stress points of each individual, leading to inadequate support and functionality.
Innovation Solution
The development of a multi-section shell protective device with a hinge system and variable thickness, manufactured using additive manufacturing, which is designed to fit the contours of the residual limb and accommodate stress distribution, incorporating a foam layer and adjustable straps for secure fitting and enhanced functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional prosthetic and orthotic devices are used, then manufacturing simplicity is maintained, but comfort and secure fit for post-operative residual limbs deteriorates due to failure to account for unique anatomical structure and varying stress points
Solution Approach 1:
The protective device employs variable thickness design where the shell thickness varies across different regions to match the unique anatomical structure and stress distribution of the residual limb. Thicker sections provide support in high-stress areas while thinner sections enhance comfort in low-stress areas, resolving the contradiction between manufacturing simplicity and customized fit comfort.
Solution Approach 2:
The device incorporates a foam layer positioned within the shell before final assembly, which is pre-configured to conform to the residual limb's anatomical contours. This preliminary action ensures that the device is pre-adapted to the user's unique anatomy, improving comfort and secure fit without complicating the manufacturing process.
2Device complexity
If conventional prosthetic and orthotic devices are used, then device structure remains simple, but functionality and support for varying stress points deteriorates
Solution Approach 1:
The shell incorporates variable thickness with strategically positioned thicker sections aligned with anatomical stress points and thinner sections in low-stress areas. This local differentiation provides enhanced support and functionality where needed while maintaining overall structural simplicity, resolving the contradiction between device complexity and reliability.
Solution Approach 2:
The hinge system connects multiple sections of the shell, enabling dynamic movement and adjustment that adapts to varying stress points during use. This dynamic capability enhances support and functionality without requiring a completely complex structural design, as the simplicity is maintained through modular sectioning rather than monolithic complexity.
3Manufacturing precision
If additive manufacturing with variable thickness is used, then anatomical fit and stress distribution are improved, but manufacturing complexity increases
Solution Approach 1:
The additive manufacturing process utilizes parameter changes by varying the shell thickness parameter across different spatial locations to match anatomical contours and stress distribution patterns. This approach achieves high anatomical fit precision while the manufacturing process complexity is managed through software-controlled parameter variation rather than physical tooling complexity.
Solution Approach 2:
The additive manufacturing process serves multiple functions simultaneously: it creates the variable thickness shell, integrates the hinge mechanisms, and positions the foam layer, all in a single manufacturing approach. This multi-functionality reduces overall manufacturing process complexity despite the precision requirements, as one process replaces multiple sequential operations.
4Ease of operation
If multi-section shell with hinge system is used, then ease of application and removal is improved, but device structure complexity increases
Solution Approach 1:
The protective device is divided into multiple shell sections connected by hinge systems, allowing the device to be opened and closed like a book. This segmentation enables easy application and removal by simply opening the hinges, while the structural complexity is managed through standardized connection interfaces rather than complex assembly mechanisms.
Solution Approach 2:
The hinge system provides dynamic movement between shell sections, transitioning from a closed protective configuration to an open application/removal configuration. This dynamic capability improves ease of operation while the structural complexity remains controlled through simple rotational joints rather than complex mechanical systems.
Data Source
AI summary
A protective device for an upper extremity post-operative residual limb of a user. The protective device includes a multi-section shell having a shape that corresponds to an anatomical structure of the upper extremity post-operative residual limb of the user. The protective device also includes a hinge coupled with a first section and a second section of the multi-section shell, the hinge configured to facilitate relative rotation of the first section and the second section to transition the protective device between an open configuration and a closed configuration. The multi-section shell is configured to receive one or more attachments to increase functionality of the upper extremity post-operative residual limb of the user.