Technical note: Computer-manufactured inserts for prosthetic sockets.

Area of Science:

• Biomedical Engineering
• Materials Science
• Prosthetics and Orthotics

Background:

• Traditional prosthetic socket fabrication can be time-consuming and labor-intensive.
• Custom inserts may improve prosthetic fit and comfort for trans-tibial prosthesis users.
• Advancements in 3D printing offer new possibilities for personalized medical devices.

Purpose of the Study:

• To design and fabricate custom plastic inserts for trans-tibial prosthesis sockets using computer-aided design (CAD) and 3D printing.
• To evaluate the shape quality and durability of these custom inserts over a four-week period.
• To explore the potential benefits of computer-manufactured inserts compared to traditional methods.

Main Methods:

• Utilized CAD software to design custom plastic inserts.
• Employed a tabletop 3D additive manufacturing system for fabrication.
• Assessed insert shape quality and socket fit immediately after insertion and after four weeks of wear.

Main Results:

• The fabricated inserts remained properly positioned and intact throughout the four-week testing period.
• Immediately after insertion, inserts caused a slight under-sizing of the socket (mean 0.11mm).
• After four weeks, the under-sizing reduced significantly (mean 0.03mm), indicating insert settlement.

Conclusions:

• Custom 3D-printed inserts demonstrate good shape retention and durability for trans-tibial prosthesis sockets.
• The inserts exhibit a settling effect over time, improving socket fit.
• Integrating insert design into existing prosthetic CAD software could streamline fabrication and enhance customization.