3D Printed Prosthetic Socket Inserts for Crack-Resistant Attachment
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Solution Overview
Problem
Conventional 3D printing technologies for prosthetic devices face limitations in material range and strength, leading to brittle and weak structures, particularly when embedding connection inserts, which often result in cracking or breaking due to stress concentration and inadequate material integration.
Innovation Solution
The use of a custom-designed connection insert with an X-shape or U-shape configuration embedded within the 3D printed socket, allowing for even stress distribution and increased material usage, combined with the ability to print multiple materials simultaneously, including rigid and soft materials, to enhance the durability and longevity of prosthetic devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional 3D printing is used to manufacture prosthetic devices, then rapid prototyping and complex layered designs are achieved, but the devices are weak and brittle with limited material range
Solution Approach 1:
The patent employs composite materials by combining multiple materials with different properties (rigid, soft, flexible) in a single 3D printed prosthetic device. This allows the device to achieve both structural strength from rigid materials and comfort/durability from soft materials, resolving the contradiction between rapid manufacturing and device strength.
2Adaptability or versatility
If connection inserts are embedded in 3D printed sockets, then component attachment is enabled, but cracking and breaking occur due to stress concentration
Solution Approach 1:
The patent applies local quality by creating a connection insert with varying material densities and properties at different locations. The insert has a rigid outer shell for structural support and attachment, while the inner core uses softer, more flexible materials to distribute stress evenly, preventing crack propagation at the attachment point.
Solution Approach 2:
The connection insert is constructed using composite materials with different mechanical properties - a rigid outer layer for attachment functionality and a flexible inner core for stress distribution. This composite structure enables component attachment while preventing cracking and breaking under load.
3Ease of manufacture
If single material 3D printing is used, then manufacturing simplicity is maintained, but device durability and functionality are limited
Solution Approach 1:
The patent implements multi-functionality by integrating multiple materials (rigid, soft, flexible) into a single 3D printed prosthetic device. This allows one device to perform multiple functions - structural support, comfort, durability - that would otherwise require separate components, maintaining manufacturing simplicity while extending device longevity.
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 approach significantly improves the strength and durability of 3D printed prosthetic devices by distributing stress evenly and allowing for the use of multiple materials, reducing the risk of cracking and breaking, thereby extending the device's usability and functionality.
Implementation Method 1
The socket is formed by a three-dimensional printing process
Data Source
AI summary
Systems and methods for creating custom-fit prosthetic devices, orthotic devices, and related medical devices via three-dimensional printing (3D printing) or additive manufacturing techniques are described. Through the described systems and methods, a residual limb or other body part of a patient is scanned and analyzed to determine measurements and characteristics of the residual limb. The measurements and characteristics of the residual limb are used to design a customized device for the residual limb. The customized device uses multiple different materials. For example, the customized device may use a first material for a frame and a second material for a liner, wherein the first material is more rigid than the second material. The customized device is fabricated using a three-dimensional printer that is capable of printing and bonding multiple different materials at the same time.