Prosthetic Socket Insert Geometry for Stress-Resistant 3D Printing
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Solution Overview
Problem
Existing 3D printing technologies are limited by the range of materials used, which are often weak and brittle, and the integration of connection inserts in prosthetic devices can cause cracking and breaking due to stress concentration.
Innovation Solution
The use of a connection insert with an X- or U-shape design embedded within the socket, which distributes stress evenly and allows for multiple materials to be used, including metals, to enhance durability and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional 3D printing materials are used, then manufacturing capability is improved, but strength and durability deteriorate due to weak and brittle material properties
Solution Approach 1:
The patent employs composite materials by combining 3D printed socket components with metal connection inserts. The socket is printed using 3D printing technology while connection inserts are made from metal materials, creating a composite structure that leverages the manufacturing flexibility of 3D printing and the superior strength of metal to resolve the contradiction between ease of manufacture and material strength.
2Strength
If connection inserts are integrated into the socket, then structural strength is improved, but reliability deteriorates due to stress concentration causing cracking and breaking
Solution Approach 1:
The patent applies local quality by designing connection inserts with specific geometric features (such as rounded corners, distributed hole patterns, and gradual transitions) that locally modify stress distribution. These design features concentrate stress away from critical points and distribute it more evenly throughout the connection insert and socket interface, preventing crack initiation while maintaining structural strength.
3Device complexity
If limited materials are used in 3D printing, then device complexity is reduced, but adaptability deteriorates due to inability to use multiple material types
Solution Approach 1:
The patent segments the prosthetic device into distinct components that can be manufactured using different materials and processes. The socket is 3D printed using appropriate materials for patient-specific fitting, while connection inserts are separately manufactured from metal materials optimized for mechanical strength and threading. This segmentation allows each component to be optimized independently, achieving material versatility without excessive overall device complexity.
Data Source
AI summary
A prosthetic device includes a socket, fasteners, and a pylon. The socket defines a cavity configured to receive a residual limb of a user. The socket includes a base defining multiple blind-holes. Each of the fasteners are configured to be received within a corresponding one of the blind-holes. The fasteners each include internal threads. The pylon includes through-holes that are aligned with a corresponding one of the blind-holes. The pylon is configured to be directly coupled with the base of the socket through externally threaded fasteners that extend through the through-holes and threadingly couple with the internal threads of the plurality of fasteners.