Thermoplastic Prosthetic Socket Strut Thermal Reforming
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Solution Overview
Problem
Conventional prosthetic socket fabrication methods are costly, time-consuming, and inefficient due to the reliance on custom-made positive molds, which do not effectively address the need for efficient and scalable manufacturing and fitting of prosthetic sockets, especially considering geographical and logistical challenges in the distribution of information and components between patients, doctors, prosthetists, and manufacturers.
Innovation Solution
A thermal reforming apparatus and method using a reconfigurable pin tool device and molding rig to reshape thermoplastic articles, allowing for the digital transfer of a residual limb's profile to a prosthetic socket strut, enabling the creation of custom-fitted prosthetic sockets through thermally reforming thermoplastic or thermoplastic-fiber composite materials to match the contours of a residual limb.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional custom-made positive molds are used for prosthetic socket fabrication, then the fit and comfort for patients is improved, but the production time and costs increase
Solution Approach 1:
The patent uses digital copying (3D scanning) to create a digital model of the residual limb, which is then used to manufacture the prosthetic socket. This eliminates the need for physical positive molds while preserving the custom-fit advantage, significantly reducing production time and costs.
Solution Approach 2:
The patent replaces the mechanical process of creating and using physical positive molds with a digital system. 3D scanning captures limb geometry, and computer-aided manufacturing produces the socket, eliminating the time-consuming manual mold-making process while maintaining customization.
2Reliability
If conventional custom-made positive molds are used for prosthetic socket fabrication, then the fit and comfort for patients is improved, but the manufacturing scalability and efficiency worsen
Solution Approach 1:
Digital copying enables the prosthetic socket manufacturing process to be replicated and scaled efficiently. The digital model can be stored, transmitted, and used for manufacturing without the logistical burden of physical molds, improving productivity while maintaining custom fit.
Solution Approach 2:
The patent changes the state of the manufacturing process from physical to digital. This parameter change enables faster production, easier storage, and improved scalability while maintaining the ability to produce customized prosthetics with precise fit and comfort.
3Manufacturing precision
If physical positive molds are used for prosthetic socket fabrication, then custom fitting is achieved, but the logistical challenges in distribution and storage increase
Solution Approach 1:
The patent replaces physical positive molds with digital copies (3D scans) of the residual limb. These digital models can be easily stored, transmitted, and accessed without the logistical challenges of physical molds, while still enabling precise custom fitting through computer-aided manufacturing.
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 reduces production time and costs by enabling the efficient fabrication of custom-fitted prosthetic sockets with improved fit and comfort for patients, while minimizing logistical challenges through the use of digital data and thermally reformable materials.
Implementation Method 1
heating a thermoplastic article to render it malleable
Implementation Method 2
pressing the malleable thermoplastic article against the reconfigurable pin tool device to reform it into the desired shape
Data Source
AI summary
Embodiments of the provided technology relate to methods, devices, and systems that drive a transfer of the digital profile of residual limb contours to a thermoplastic article such as a prosthetic socket strut. A method of reforming a thermoplastic article to assume a desired shape, such as a contour that replicates or is complementary to the contour of a body portion, may include heating a thermoplastic article to render the article malleable. The method may further include placing the thermoplastic article against a molding surface having a desired shape that replicates the portion of the body part. Next, the thermoplastic article may be pressed against the molding surface with a compliant molding press to reform at least a portion of the article into the desired shape. The reformed thermoplastic article may then be removed from the molding surface, the article retaining the desired shape after removal.