Modular Prosthetic Socket with 3D Printed Insert
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional prosthetic socket systems often require time-consuming and costly custom manufacturing, lack adjustability, and do not provide optimal fit and comfort for residual limbs, as they rely on rigid outer layers that need to be individually crafted for each patient.
Innovation Solution
A modular prosthetic socket system comprising a customized, three-dimensionally printed insert socket with an inner contour matching the residual limb and a standardized outer shell socket, allowing for adjustable fit and integration of inflatable bladders for pressure adjustment, along with a vacuum-assisted attachment system for improved comfort and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional custom manufacturing is used for prosthetic sockets, then fit and comfort are improved, but manufacturing time and cost increase
Solution Approach 1:
The prosthetic socket is divided into two distinct components: a standardized outer shell socket that can be pre-manufactured, and a customized inner insert socket that is three-dimensionally printed to match the patient's residual limb. This segmentation allows the outer shell to be produced using efficient standardized processes while the inner insert provides custom fit, thereby reducing overall manufacturing time while maintaining fit and comfort quality.
2Manufacturing precision
If rigid outer layers are individually crafted for each patient, then fit is improved, but manufacturing cost and time increase
Solution Approach 1:
The socket system separates the fit-function into the customized inner insert from the structural function in the standardized outer shell. This allows the outer shell to be manufactured once and reused, significantly reducing manufacturing cost and time while the inner insert provides the necessary custom fit.
Solution Approach 2:
The standardized outer shell socket is designed to be universal and can accommodate multiple patients through the use of different customized inner inserts. This multi-functionality reduces the need for individual crafting of entire sockets, lowering manufacturing costs and time while maintaining patient-specific fit through the inner inserts.
3Productivity
If modular design with pre-manufactured outer shell is used, then manufacturing efficiency is improved, but customization capability must be maintained
Solution Approach 1:
The modular design segments the socket into a standardized outer shell and a customized inner insert, allowing the outer shell to be pre-manufactured for efficiency while the inner insert maintains customization capability through three-dimensional printing tailored to each patient's anatomy.
Solution Approach 2:
The customized inner insert socket is nested within the standardized outer shell socket. This nesting arrangement allows the smaller customized component to be housed within the larger standardized component, combining manufacturing efficiency with customization capability in a unified structure.
4Ease of operation
If adjustable pressure system is added, then comfort is improved, but device complexity increases
Solution Approach 1:
The system incorporates an adjustable pressure mechanism using pneumatic or hydraulic principles, allowing pressure to be modified within the socket to improve comfort. This approach provides adjustable functionality without requiring complex mechanical structures, thereby limiting the increase in device complexity.
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 system reduces manufacturing time, enhances fit and comfort by allowing for adjustable pressure and secure attachment, while enabling the use of stronger, pre-manufactured outer shell sockets, thus improving the overall efficiency and effectiveness of prosthetic fitting.
Implementation Method 1
a customized, three-dimensionally printed insert socket with an inner contour matching the residual limb
Implementation Method 2
a vacuum-assisted attachment system for improved comfort and stability
Data Source
AI summary
Systems and methods are described herein for a prosthetic device that includes a rigid outer shell socket with an inner surface contour. A prosthetic insert socket is manufactured via a manufacturing process, such as three-dimensional printing, to have an outer contour that corresponds to the inner surface contour of the premade outer shell socket. The prosthetic insert socket is manufactured to have an inner contour that corresponds to a residual limb surface contour of a patient.