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Enhancing the Strength of 3D-Printed Polymer Exoprosthetic Socket by Localized Non-Planar Continuous Carbon Fiber
Daria Dolgikh1, Evgeniy Lobov1, Igor Bezukladnikov2
1Laboratory of Mechanics of Biocompatible Materials and Devices, Perm National Research Polytechnic University, 29 Komsomolsky Ave., 614990 Perm, Russia.
Polymers
|April 26, 2025
Summary
This study enhances 3D-printed transtibial exoskeleton sockets using carbon fiber rods. This reinforcement strengthens high-load areas, reducing stress concentrations in prosthetic devices.
Area of Science:
- Biomedical Engineering
- Materials Science
- Additive Manufacturing
Background:
- 3D-printed orthopedic sockets face structural integrity challenges.
- Enhancing prosthetic device strength is crucial for patient outcomes.
Purpose of the Study:
- To investigate non-planar reinforcement strategies for 3D-printed transtibial exoskeleton sockets.
- To improve the structural integrity and load-bearing capacity of prosthetic devices.
Main Methods:
- Utilized multi-axis additive manufacturing to integrate continuous carbon fiber prepreg rods.
- Employed numerical modeling with progressive failure analysis to simulate damage accumulation.
- Developed and tested prototypes of reinforced polyamide sockets.
Main Results:
- Numerical simulations accurately predicted crack initiation in the distal socket section.
- Localized carbon rod reinforcement effectively strengthened high-load regions.
- Demonstrated a significant reduction in stress concentrations within reinforced prostheses.
Conclusions:
- Optimizing internal reinforcement architecture in stress concentrator zones improves product strength.
- Multi-axis non-planar additive manufacturing enables precise reinforcement of complex socket geometries.
- Carbon fiber reinforcement is a viable strategy for enhancing 3D-printed orthopedic devices.
