Prosthetic Limb Kit Rapid On-Site Assembly
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Solution Overview
Problem
Conventional prosthetic limb manufacturing processes require lengthy off-site production, leading to poor fit due to changes in the amputee's stump shape, size, or dimensions over time, necessitating repeated casting and manufacturing, which is time-consuming and often results in a suboptimal fit.
Innovation Solution
A portable kit comprising a sock, separator bag, distal pad, flexible sheath, casting sock, outer coupling member, casting tape, dowel, pylon, and artificial foot components, allowing for on-site assembly and customization of a prosthetic leg using water-activated settable materials to create a secure and adjustable fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional off-site manufacturing process is used, then manufacturing precision can be maintained, but production time becomes excessively long and fit accuracy deteriorates due to stump changes
Solution Approach 1:
The patent applies preliminary action by pre-assembling the prosthetic components (socket, pylon, foot, shin) in a portable kit before patient use. The socket is pre-formed with attachment mechanisms ready for rapid connection, eliminating the need for time-consuming on-site manufacturing while maintaining fit accuracy through pre-cast precision. This allows the prosthetic to be prepared in advance and delivered quickly to the patient.
Solution Approach 2:
The patent segments the prosthetic limb into multiple detachable components (socket, pylon, foot, shin) that can be manufactured separately with high precision and then rapidly assembled on-site. This segmentation enables each component to be optimized and manufactured independently using precise casting methods, while the overall assembly time is reduced because components don't require complex integrated manufacturing.
2Reliability
If traditional manufacturing process is used, then quality control can be maintained, but device complexity and cost increase due to multiple casting and manufacturing cycles
Solution Approach 1:
Quality control is maintained through preliminary action by performing all precision casting and quality inspections during off-site manufacturing of individual components. Each component (socket, pylon, foot) is cast and quality-tested before being assembled into the final prosthetic, ensuring high reliability without requiring complex multi-cycle manufacturing processes on-site.
3Productivity
If rapid on-site assembly is implemented, then production time is reduced, but manufacturing precision may deteriorate without proper equipment
Solution Approach 1:
The patent resolves this contradiction by performing precision manufacturing in advance during off-site production of individual components. The socket, pylon, and foot are each precisely cast and fitted before assembly. On-site, only simple attachment operations are required, which maintain precision through pre-designed attachment mechanisms rather than requiring complex precision equipment during rapid assembly.
Solution Approach 2:
The patent uses copying by creating a precise cast model of the patient's stump during the initial fitting process. This cast serves as a template that is used to manufacture the socket with high precision. The cast accurately captures the stump's geometry, and this information is replicated in the socket manufacturing process, ensuring precise fit even though the final assembly occurs rapidly on-site.
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
Enables immediate fitting and use of a prosthetic limb, reducing production time to under an hour, improving fit accuracy, and significantly lowering costs, making it accessible to remote or impoverished individuals at a fraction of the cost of traditional prosthetics.
Implementation Method 1
a casting sock comprising a fabric containing a water activated settable material that, after activation, is adapted to fit over the flexible sheath, the inner coupling member, the distal pad, and at least part of the separator bag and the sock
Implementation Method 2
an adhesive for attaching the foot components together, for attaching the pylon or the wooden dowel to the hole of the foot component and to the socket opening of the outer coupling member
Data Source
AI summary
A prosthetic limb is made from a portable kit that is of relatively low cost and easy to assemble and custom fit to a person in need so that the person can wear the prosthetic immediately, without having to wait for the prosthetic to be manufactured off-site. The embodiments include a below the knee device and an above the knee device that includes an artificial knee. The improved prosthetic is suited for replacing a missing leg but can also be adapted to replace another body part such as an arm, hand or foot.