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Streamlined custom manufacturing for optimized 3D printed prostheses through 3D pressure mapping.

Hadi Moeinnia1, Carl Ganzert2, Loren Schubert2

  • 1Additive Manufacturing Laboratory, School of Mechatronic Systems Engineering, Simon Fraser University, Surrey, V3T ON1, Canada.

Biosensors & Bioelectronics
|February 26, 2026
PubMed
Summary
This summary is machine-generated.

This study presents a new digital workflow for prosthetic socket design using 3D pressure mapping and lattice structures. This innovative approach enhances comfort and reduces impact forces for amputees.

Keywords:
Additive manufacturingCellular structuresDensity gradingPressure mappingProsthetic socketWearable devices

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Area of Science:

  • Biomedical Engineering
  • Materials Science
  • Rehabilitation Engineering

Background:

  • Prosthetic socket design significantly impacts user comfort and mobility.
  • Current methods often fail to adequately address dynamic pressure variations.
  • Improving the limb-socket interface is crucial for prosthetic performance.

Purpose of the Study:

  • To develop and validate a novel digital workflow for prosthetic socket design.
  • To integrate 3D pressure mapping with density-graded lattice structures.
  • To enhance comfort and reduce impact forces at the limb-socket interface.

Main Methods:

  • A wearable liner with capacitive, origami-inspired pressure sensors was developed.
  • Dynamic contact pressures were measured on a transfemoral amputee during various static and dynamic activities.
  • Pressure data were processed to create a 3D pressure map guiding density grading of lattice structures (Gyroid, Diamond, Neovius).
  • Finite Element Analysis (FEA) was used to evaluate energy absorption.

Main Results:

  • Peak pressures reached up to 7500 kPa, with ramp descent posing critical load challenges.
  • The 3D pressure map informed the density grading of cellular infill structures.
  • Graded Gyroid structures absorbed significantly more energy (up to 1600% during standing, 1290% during walking) compared to solid infills.
  • The novel design approach effectively mitigated localized contact pressures.

Conclusions:

  • The study validates a pressure-informed, additively manufactured prosthetic socket design.
  • This approach has the potential to significantly enhance user comfort and prosthetic performance.
  • The integration of 3D pressure mapping and density-graded lattice structures offers a promising advancement in prosthetic technology.