3D Printed Prosthetic Socket with Laminated Stabilizing Element
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Solution Overview
Problem
Existing 3D printed prosthetic sockets lack sufficient structural strength for long-term use under various environmental conditions, limiting their durability and comfort for prosthetic wearers.
Innovation Solution
A method involving 3D printing a base shaft with a stabilizing element made of a stronger material, such as prepregs, applied through lamination, gluing, or welding, to enhance structural strength while maintaining the comfort and customization of the prosthetic socket, using non-contact 3D data creation methods and inhomogeneous wall thickness for optimal stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a prosthetic socket is manufactured using 3D printing with processable plastics, then manufacturing time and costs are reduced, but structural strength is insufficient for long-term use under various environmental conditions
Solution Approach 1:
The patent applies composite materials by combining a 3D-printed base socket made of processable plastic with additional stabilizing elements made of materials having higher structural strength. This composite structure allows the base socket to maintain manufacturing efficiency while the added stabilizing elements provide the necessary structural strength for long-term use under various environmental conditions.
2Ease of manufacture
If a prosthetic socket is manufactured using 3D printing with processable plastics, then manufacturing costs are reduced, but structural strength is insufficient for long-term use under various environmental conditions
Solution Approach 1:
The patent applies composite materials by combining a 3D-printed base socket made of processable plastic with additional stabilizing elements made of materials having higher structural strength. This composite structure allows the base socket to maintain manufacturing efficiency while the added stabilizing elements provide the necessary structural strength for long-term use under various environmental conditions.
3Ease of operation
If the inner contour of the base socket corresponds exactly to the outer contour of the stump, then comfort is maximized, but structural strength is reduced
Solution Approach 1:
The patent applies composite materials by combining a 3D-printed base socket made of processable plastic with additional stabilizing elements made of materials having higher structural strength. This composite structure allows the base socket to maintain manufacturing efficiency while the added stabilizing elements provide the necessary structural strength for long-term use under various environmental conditions.
Solution Approach 2:
The patent applies local quality by providing stabilizing elements at specific locations on the base socket where structural strength is needed, rather than uniformly throughout. This allows the inner contour to maintain close correspondence to the stump for comfort while adding strength only where required by the composite structure.
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 method produces prosthetic sockets with improved structural strength and comfort, reducing manufacturing time and costs, and ensuring a high-quality, market-ready product tailored to individual requirements with enhanced durability and wearability.
Implementation Method 1
a base socket is produced from a first material in a 3D printing process using the 3D data set
Implementation Method 2
at least one stabilizing element made of a second material is applied to the base socket, e.g., laminated, glued, welded, or positively secured
Data Source
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Figure 2
AI summary
The invention relates to a method for manufacturing a prosthetic socket (12) in which a 3D data set (20) of an outer contour (16) of a residual limb to which a prosthetic socket (12) is to be attached is created, a base socket (14) made of a first material is produced in a 3D printing process using the 3D data set (20), wherein an inner contour (18) of the base socket (14) corresponds to the outer contour (16) of the residual limb (10), wherein at least one stabilizing element (32) made of a second material is laminated onto the base socket (14).