Single-Step 3D Printing of Bio-Inspired Printable Joints Applied to a Prosthetic Hand

Single-step 3D printing, which can manufacture complicated designs without assembly, has the potential to completely change our design perspective, and how 3D printing products, rather than printing static components, ready-to-use movable mechanisms become a reality. Existing 3D printing solutions are challenged by precision limitations, and cannot directly produce tightly mated moving surfaces. Therefore, joints must be designed with a sufficient gap between the components, resulting in joints and other mechanisms with imprecise motion. In this study, we propose a bio-inspired printable joint and apply it to a Single sTep 3D-printed Prosthetic hand (ST3P hand). We simulate the anatomical structure of the human finger joint and implement a cam effect that changed the distance between the contact surfaces through the elastic bending of the ligaments as the joint flexed. This bio-inspired design allows the joint to be single-step 3D printed and provides precise motion. The bio-inspired printable joint makes it possible for the ST3P hand to be designed as a lightweight (∼255 g), low-cost (∼$500) monolithic structure with nine finger joints and manufactured via single-step 3D printing. The ST3P hand takes ∼6 min to assemble, which is approximately one-tenth the assembly time of open-source 3D printed prostheses. The hand can perform basic hand tasks of activities of daily living by providing a pulling force of 48 N and grasp strength of 20 N. The simple manufacturing of the ST3P hand could help us take one step closer to realizing fully customized robotic prosthetic hands at low cost and effort.