3D-Printed Prosthetic Socket With Single-Pass Solid Walls
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Solution Overview
Problem
Conventional 3D printing methods for prosthetic sockets fail to produce clear and structurally sound sockets, requiring additional hardware components for reinforcement due to lack of clarity and structural strength.
Innovation Solution
A method involving a 3D printing nozzle with an enlarged nozzle face to print a solid wall perimeter in a single pass, combined with stiffener elements, ensuring transparency and structural integrity without voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional 3D printing methods are used to print prosthetic sockets, then the printing process can be completed, but the resulting sockets lack structural strength and clarity
Solution Approach 1:
The patent changes the printing parameters by using a single-pass printing method with specific nozzle settings to achieve both structural integrity and clarity. The nozzle temperature, printing speed, and material flow rate are optimized to create dense, void-free structures that are both strong and transparent.
Solution Approach 2:
The patent uses composite printing materials that combine optical clarity with structural strength. The material formulation includes transparent polymers reinforced with additives or fillers that enhance mechanical properties while maintaining optical transparency, allowing the socket to be both strong and visually inspectable.
2Ease of manufacture
If conventional 3D printing methods are used, then printing can be performed, but additional hardware components must be attached to reinforce the socket
Solution Approach 1:
The patent merges the reinforcement function into the printing process itself by forming stiffener elements directly during single-pass printing. The stiffeners are integrated into the socket structure as it is being printed, eliminating the need for separate attachment operations and reducing overall device complexity.
Solution Approach 2:
The patent performs preliminary action by pre-forming the stiffener elements and attachment features during the initial printing process. The socket is printed with built-in reinforcement structures and mounting features already in place, so no additional hardware needs to be attached later, simplifying the manufacturing process.
3Quantity of substance
If multiple passes of the printing nozzle are used to achieve desired thickness, then material coverage is improved, but voids are created that reduce clarity
Solution Approach 1:
The patent changes the printing parameters by using a single-pass method with increased material deposition rate and optimized nozzle settings. The nozzle is configured to deposit sufficient material thickness in one pass without creating voids, achieving both adequate thickness and void-free clarity simultaneously.
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 results in a transparent, structurally sound prosthetic socket that can be immediately attached to a pylon, allowing visual inspection and ensuring user comfort and stability.
Implementation Method 1
printing a solid wall perimeter of the prosthetic socket with a width achieved in a single pass of a printing nozzle
Implementation Method 2
dispersing a deposited printing material using the printing nozzle to achieve a desired thickness of the solid wall perimeter in the single pass
Data Source
AI summary
A method for 3D printing a prosthetic socket from a digital model, including printing a solid wall perimeter of the prosthetic socket with a width achieved in a single pass of a printing nozzle, and forming a plurality of stiffener elements proximate a bottom end of the prosthetic socket, as a function of the printing the solid wall perimeter, is provided. Also provided is a 3D printed prosthetic socket including an upper portion, a lower portion configured to be attached to a prosthetic pylon, and a plurality of stiffener elements radially extending from the lower portion, wherein the upper portion, the lower portion, and the plurality of stiffener elements are printed as a solid wall construction comprised of a printing material deposited using only a single pass of a printing nozzle.