Additive Manufactured Prosthetic Footshell Lattice

The patent applies porous lattice structures within the footshell components, creating a network of interconnected struts and voids that reduce material density while maintaining structural integrity. This porous architecture allows significant weight reduction compared to solid materials while preserving adequate strength through the geometric configuration of the lattice framework.

The patent combines multiple materials with different properties - using thermoplastic materials for the footshell base and integrating carbon fiber reinforcement in specific regions. This composite approach allows optimization of both weight and strength by placing high-strength materials only where structurally necessary, rather than using heavy materials throughout.

The patent implements spatially varying lattice structures where different regions of the footshell have different strut densities, orientations, and geometries. High-stiffness regions are concentrated in areas experiencing maximum loads (such as the heel and toe regions), while more compliant regions are located in areas requiring flexibility for natural foot-like motion. This local differentiation allows the prosthesis to withstand peak loads while maintaining adaptability across various activity levels.

The patent designs the footshell with dynamic characteristics through its lattice structure that can adapt its effective stiffness during the gait cycle. The geometric configuration of the lattice allows for non-linear mechanical response, providing increased stiffness during high-load phases (such as heel strike) and greater compliance during lower-load phases, enabling the structure to dynamically adjust to varying activity demands.

The patent integrates multiple functions into a single additive manufacturing process. The footshell, reinforcement elements, and structural features are all created in one continuous printing operation using thermoplastic materials, eliminating the need for separate molding, assembly, and reinforcement attachment steps. This merging of manufacturing operations reduces overall complexity despite the sophistication of the resulting structure.

The patent leverages the ability of additive manufacturing to easily modify design parameters such as lattice geometry, strut thickness, and material deposition patterns. These parameter changes can be implemented simply by updating digital model files without requiring new tooling or manufacturing processes, providing manufacturing flexibility and reducing complexity compared to traditional methods that would require physical tooling changes for design iterations.