Three-dimensional printing in prosthetics: Method for managing rapid limb volume change

Area of Science:

• Prosthetics and Orthotics
• Biomedical Engineering
• Additive Manufacturing

Background:

• Residual limb volume changes frequently during post-amputation recovery or with body mass fluctuations.
• This necessitates regular socket adjustments or replacements to ensure proper prosthetic fit.
• Current methods for managing volume changes can be time-consuming and costly.

Purpose of the Study:

• To assess the feasibility of using 3D-printed inserts to prolong prosthetic socket service life.
• To evaluate the impact of these inserts on socket fit and user comfort.
• To explore a novel solution for managing residual limb volume fluctuations.

Main Methods:

• Fabricated an oversized transtibial prosthetic socket to simulate significant limb volume loss.
• Utilized digital scans of well-fitting and oversized sockets to design a 3D-printed insert.
• Restored socket fit using the custom-designed 3D-printed insert.

Main Results:

• Walking test distances decreased with an oversized socket alone but remained stable with the insert.
• Participant comfort scores remained high (8+) across all tested conditions.
• The 3D-printed insert effectively restored the fit of the oversized prosthetic socket.

Conclusions:

• Three-dimensional (3D) printing offers a valuable tool for prosthetists to manage residual limb volume changes.
• Replaceable 3D-printed inserts can maintain prosthetic socket fit and comfort during volume fluctuations.
• This technology may reduce the need for complete socket refabrication, extending socket service life.