Designing Custom Mechanics in Running-Specific Prosthetic Feet via Shape Optimization

Running-specific prosthetic feet are curved cantilever springs, distinguished from ordinary prosthetic feet by their size, shape, and greater ability to store and return elastic potential energy. Finite element analyses show how modifications to prosthesis shape alter the multidimensional and nonlinear mechanics, but designers seeking to prescribe custom mechanics are limited by the complex constraints and high dimensionality of possible geometries.

We introduce two simple formulations for describing foot mechanics, and use them with a custom spline-based shape optimization to generate new prosthetic foot shapes given desired endpoint mechanics. We then tackle a relevant example problem using this approach, designing and characterizing three running-specific prosthetic feet with similar vertical and angular deflections but varied horizontal deflections, with the expectation that knee extension moments would increase with anterior deflection of the toe. Finally, we compare the prostheses' endpoint mechanics and resulting biomechanics in an athlete with unilateral transfemoral amputation.

The shape optimization was able to derive shapes that substantially alter prosthesis mechanics along all dimensions of endpoint behavior, and benchtop testing validated the behavior of two new feet constructed from the optimization. The subject's knee moments increased with horizontal endpoint deflection as expected.

We developed and validated a shape optimization tool using a simplified formulation of foot behavior to achieve desired running prosthesis mechanics.

With this framework, researchers can begin to elucidate the link between prosthesis mechanics and athlete biomechanics and performance.