A personalised prosthetic liner with embedded sensor technology: a case study.

Area of Science:

• Biomedical Engineering
• Prosthetics and Orthotics
• Materials Science

Background:

• Monitoring residual limb/prosthesis interface parameters is crucial for prosthetic socket design.
• Integrating sensors into sockets is complex and can cause discomfort.
• Personalized prosthetic liners with embedded sensors offer a potential solution for improved comfort and functionality.

Purpose of the Study:

• To present a novel approach for manufacturing fully personalized prosthetic liners with integrated sensors.
• To demonstrate the feasibility of using 3D scanning and Computer Numeric Control (CNC) machining for custom liner fabrication.
• To embed temperature and humidity sensors for monitoring the prosthetic socket microclimate.

Main Methods:

• 3D scanning of a transtibial amputee's residual limb to create a digital model.
• Manufacturing a personalized liner using cryogenic CNC machining of soft elastomer.
• Embedding twelve Hygrochron Data Loggers for temperature and humidity measurement directly into the liner.
• Assessing sensor outputs during resting and walking activities, comparing with the existing liner.

Main Results:

• The liner machining process took approximately 4 hours.
• Skin temperature reached a plateau 15 minutes after donning; physical activity increased temperature.
• The new liner demonstrated superior thermal properties, showing a 4% reduction in skin temperature compared to the existing liner.
• Humidity levels increased throughout the observation period.

Conclusions:

• A novel method for creating personalized prosthetic liners with embedded sensors has been developed.
• This approach allows for seamless sensor integration, enabling measurement of intra-socket microclimate conditions.
• The technology facilitates the design of advanced, personalized socket solutions and enables dynamic assessment of residual limb behavior within the socket.