Prosthetic Socket Virtual Adjustment for Faster 3D Printing
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Solution Overview
Problem
Existing methods for manufacturing prosthetic sockets are inefficient, requiring manual spatial arrangement and excessive material use, leading to weakened joints and increased costs.
Innovation Solution
A process involving virtual axial adjustment of prosthetic sockets using 3D printing, which includes obtaining physical and digital data, virtually arranging prosthetic parts, and optimizing structural design to reduce material usage and enhance comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual spatial arrangement of prosthetic socket and parts is performed, then flexibility in adjustment is maintained, but manufacturing time and complexity increase significantly
Solution Approach 1:
The patent creates a digital copy of the prosthetic socket and parts in a virtual environment, allowing spatial arrangement to be performed computationally rather than physically. The virtual model replicates all geometric and positional characteristics, enabling rapid adjustment and optimization without time-consuming manual assembly operations.
Solution Approach 2:
The patent replaces the mechanical process of manual spatial arrangement with a computational system. The virtual environment uses software algorithms to automatically position and orient prosthetic components, substituting human manual manipulation with automated digital processing that is both flexible and time-efficient.
2Strength
If excessive material is used during manufacturing, then structural strength is ensured, but manufacturing cost and waste increase
Solution Approach 1:
The patent employs computational algorithms to optimize material parameters such as density, thickness, and distribution. By adjusting these parameters in the virtual model before manufacturing, the system achieves the minimum necessary material quantity that ensures structural strength while minimizing waste, rather than using excessive material conservatively.
Solution Approach 2:
The patent utilizes porous or lattice structures in the virtual design, where material is distributed in an optimized pattern with voids and cellular structures. This approach maintains structural integrity through strategic material placement while significantly reducing overall material consumption compared to solid conventional designs.
3Device complexity
If intermittent printing of prosthetic socket is performed, then space for connecting adapter is created, but joint strength is weakened
Solution Approach 1:
The patent performs preliminary actions in the virtual environment to plan and optimize the printing process. The spatial arrangement of the connecting adapter is predetermined and integrated into the virtual model before printing begins, allowing continuous printing without interruptions while maintaining optimal joint strength and structural integrity.
4Productivity
If virtual axial adjustment is implemented, then manufacturing efficiency is improved, but computational complexity increases
Solution Approach 1:
The patent develops a universal virtual adjustment system that can handle multiple adjustment scenarios and prosthetic configurations through a single integrated software platform. This multi-functional system performs various computational tasks including spatial arrangement, optimization, and simulation, thereby improving manufacturing efficiency across different cases without proportionally increasing computational complexity.
Data Source
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AI summary
The invention is a method of designing and manufacturing a tailored 3D printed or standard prosthetic socket (3) for a residual limb, and a virtual adjustment of a prosthesis (6). The method of manufacturing the 3D printed or standard prosthetic socket (3) with a 3D printed distal end includes obtaining a digital surface (7) of the residual limb and information about the patient, possibly altering the digital surface (7) of the residual limb, creating a shell of the prosthetic socket (3) comprising the altered digital surface of the residual limb, virtually spatially arranging the prosthetic socket (3) and prosthetic parts, the resulting summary of design information, and sending the manufacturing data.