Modular Prosthetic Frame Using Segmented Members for Rapid Customization
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Solution Overview
Problem
Conventional prosthetic devices require significant manufacturing time and incur high production costs due to their custom nature and complexity, necessitating a more efficient fabrication method.
Innovation Solution
A prosthetic device is fabricated using an internal frame assembled from multiple longitudinal and transverse members, which are mated via peripheral slots to provide enhanced torsional rigidity and scalability, allowing for rapid production and customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional custom-manufactured prosthetics are used, then the device can be tailored to individual patients, but the manufacturing time and production cost increase significantly
Solution Approach 1:
The prosthetic device is divided into multiple discrete components including a socket component, pylon component, and foot component, each manufactured separately using standardized processes. These segmented components are then assembled together to create the complete prosthetic, enabling rapid production while maintaining customization capability through modular configuration.
Solution Approach 2:
The patent employs universal interface standards and standardized component designs that can be used across different prosthetic configurations. The socket component, pylon component, and foot component are designed with standardized connection mechanisms that allow them to be combined in various arrangements to meet different patient needs, reducing the need for custom manufacturing while maintaining adaptability.
2Adaptability or versatility
If conventional custom-manufactured prosthetics are used, then the device can be tailored to individual patients, but the production cost increases significantly
Solution Approach 1:
By segmenting the prosthetic into standardized components (socket, pylon, foot), each component can be manufactured using efficient, standardized processes rather than custom fabrication. This segmentation enables economies of scale and reduces tooling costs while maintaining the ability to customize the final assembly through different component combinations.
Solution Approach 2:
The patent utilizes additive manufacturing parameters and material selections that optimize both customization capability and production cost. By controlling manufacturing parameters such as layer thickness, infill density, and material composition during additive fabrication, the system achieves cost-effective production of customized components without requiring expensive post-processing or assembly operations.
3Ease of operation
If myoelectric prosthetics with electronic systems are used, then user fatigue is reduced, but the weight and cost increase
Solution Approach 1:
The patent employs thin-walled additive manufacturing structures and lattice infill patterns that provide sufficient structural strength while minimizing material usage. The socket component and foot component utilize optimized wall thicknesses and internal geometries that reduce weight without compromising structural integrity or user comfort, enabling lighter prosthetics that reduce user fatigue.
Solution Approach 2:
The prosthetic components are manufactured using composite materials that combine strength and lightness. The additive manufacturing process incorporates reinforcement strategies such as fiber reinforcement and optimized material distribution that create lightweight yet strong structures, reducing the overall weight of the prosthetic while maintaining the structural support needed for user comfort and reduced fatigue.
Data Source
AI summary
A prosthetic device including an internal frame assembled from multiple longitudinal members and multiple transverse members, wherein each member is substantially planar and defines peripheral slots, and wherein the longitudinal members and transverse members are arranged to mate with one another to join the longitudinal members with the transverse members. In certain embodiments, a first group of longitudinal members is radially arranged relative to a central axis extending through the transverse members, and a second group of longitudinal members is tangentially arranged relative to the central axis, preferably with lateral edges of the second group of longitudinal members extending between two different longitudinal members of the first group of longitudinal members to provide enhanced torsional rigidity. An outer shaping member, which may be tubular in shape, may be arranged to cover at least a portion of the internal frame.