Lightweight custom composite prosthetic components using an additive manufacturing-based molding technique

Area of Science:

• Biomedical Engineering
• Materials Science
• Additive Manufacturing

Background:

• 3D printing offers potential for affordable, customized prosthetics.
• Current 3D printed prosthetics lack durability and optimal function.
• Advancements in additive manufacturing are increasing quality and reducing costs.

Purpose of the Study:

• To propose a novel fabrication method for custom composite prostheses using additive manufacturing.
• To enhance the durability and functionality of 3D printed prosthetic components.
• To create affordable, customizable upper-limb prostheses that rival professional devices.

Main Methods:

• Utilized 3D printed molds within a multi-stage molding system.
• Fabricated custom finger/palm components with an epoxy foam core, composite outer shell, and urethane gripping surfaces.
• Conducted three-point bending tests and gravimetric measurements to assess stiffness and weight.

Main Results:

• The developed composite material exhibited superior stiffness compared to 3D printed and aluminum materials.
• The composite finger demonstrated the lowest weight among tested materials.
• The fabrication method allows for high customizability and cost-effectiveness.

Conclusions:

• The proposed additive manufacturing method yields custom composite prostheses with enhanced stiffness and reduced weight.
• This approach offers a substantial benefit for the development of upper-limb prostheses, improving both performance and accessibility.
• The custom composite prostheses combine the advantages of customizability, durability, and affordability.