3D-Printed Prosthetic Liner With Urethane Coating for Lower Friction
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Solution Overview
Problem
Traditional prosthetic liners made from silicone are expensive and difficult to customize, while 3D printed liners using semi-rigid materials face issues with high friction and discomfort due to rough surfaces.
Innovation Solution
A 3D printed prosthetic liner treated with a urethane-based casting resin to create a smooth, flexible, and strong interface between the residual limb and prosthetic socket, using TPU as the base material and post-processing techniques to abrade and coat the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional silicone prosthetic liners are used, then comfort and pressure resistance are improved, but manufacturing cost increases and customization becomes difficult
Solution Approach 1:
The patent changes the material parameter from traditional silicone to TPU (thermoplastic polyurethane), which allows for 3D printing manufacturing. This parameter change enables customization and reduces manufacturing cost while maintaining the necessary comfort and pressure resistance properties through controlled material composition and post-processing treatments.
Solution Approach 2:
The patent replaces the traditional molding process with 3D printing technology. This substitution allows for direct manufacturing of customized liners without complex mold sets, reducing manufacturing complexity and cost while enabling precise customization to individual patient needs.
2Ease of manufacture
If 3D printed prosthetic liners are used, then manufacturing cost decreases and customization improves, but surface friction increases causing discomfort
Solution Approach 1:
The patent introduces a post-processing treatment step that acts as an intermediary between the 3D printed liner and the skin. This treatment involves applying a coating or surface modification to reduce friction and improve comfort, while maintaining the cost-effective and customizable nature of 3D printing.
Solution Approach 2:
The patent modifies the surface parameters of the 3D printed liner through post-processing treatments such as sanding, coating, or chemical treatments. These parameter changes reduce surface friction and improve comfort without compromising the manufacturing advantages of 3D printing.
3Strength
If semi-rigid materials are used for 3D printing, then structural strength is improved, but flexibility and pliability decrease
Solution Approach 1:
The patent uses composite materials or multi-layer structures in the 3D printed liner. By combining different materials or layers with varying properties, the liner achieves both structural strength from the semi-rigid base material and the necessary flexibility through specific material selections or layer configurations.
Solution Approach 2:
The patent adjusts the material parameters during 3D printing, such as infill patterns, layer thickness, and material composition, to optimize both strength and flexibility. Post-processing treatments can further modify these parameters to achieve the desired balance between structural integrity and pliability.
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
The treated liner reduces friction, enhances flexibility, and provides structural strength, allowing for cost-effective customization and improved comfort and durability.
Implementation Method 1
The surface of the liner may be treated with one or more applications of a casting resin, and preferably a urethane-based casting resin forming a treated prosthetic liner
Implementation Method 2
post-processing techniques to abrade and coat the surface
Data Source
AI summary
A 3D printed prosthetic liner adapted to provide an interface between a residual limb and a prosthetic socket, specifically a prosthetic liner manufactured using a 3D printing device, the surface of which being treated with one or more applications of a casting resin, and preferably a urethane-based casting resin forming a treated prosthetic liner having enhanced strength and pliability.