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Related Experiment Video

Updated: Nov 21, 2025

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Additive manufacturing techniques for smart prosthetic liners.

B Oldfrey1, A Tchorzewska2, R Jackson3

  • 1Department of Mechanical Engineering, UCL, London, UK; Institute of Making, UCL, UK; Global Disability Innovation Hub, UCL, UK.

Medical Engineering & Physics
|January 19, 2021
PubMed
Summary

Researchers developed a smart prosthetic liner with embedded sensors for volume tracking and an active cooling system. This innovation aims to improve residual limb health and prosthetic socket comfort for users.

Keywords:
Active coolingAdditive manufactureNanocompositeProsthetic linerSoft materialsVolume tracking

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Area of Science:

  • Biomaterials Engineering
  • Prosthetics and Orthotics
  • Soft Robotics

Background:

  • Elastomeric liners are crucial in prosthetic sockets, but current technology has limitations in accurately conforming to the residual limb, impacting skin health.
  • Effective thermal management within prosthetic sockets is lacking, necessitating active heat removal systems.
  • Monitoring residual limb volume changes throughout the day is vital for optimizing prosthetic fit and function.

Purpose of the Study:

  • To develop advanced soft material technologies for smart prosthetic liners.
  • To integrate volume tracking capabilities and active cooling systems into prosthetic liners.
  • To create a more comfortable, responsive, and user-friendly prosthetic socket interface.

Main Methods:

  • Development of a printable nanocomposite stretch sensor system for integration into liners.
  • Implementation of a low-cost digital casting method for creating bespoke prosthetic liners.
  • Design and fabrication of a prosthetic liner incorporating embedded stretch sensors for volume monitoring.
  • Construction of a model liner featuring an integrated active cooling system.

Main Results:

  • Successful development of a printable stretch sensor system suitable for soft prosthetic liners.
  • Demonstration of a cost-effective digital casting technique for personalized liner production.
  • Creation of a functional prosthetic liner prototype with embedded sensors for residual limb volume tracking.
  • Development of a model liner incorporating an active cooling mechanism for thermal management.

Conclusions:

  • The developed smart prosthetic liner technology offers potential improvements in residual limb health and user comfort.
  • Embedded sensors for volume tracking and active cooling systems represent significant advancements in prosthetic liner functionality.
  • This soft material technology approach provides a pathway for more adaptable, repairable, and cost-effective prosthetic solutions compared to traditional custom sockets.