Innovative fracture-controlled safety device for osseo-integration-based prosthetic limbs

Area of Science:

• Biomaterials Engineering
• Orthopedic Biomechanics
• Prosthetics Design

Background:

• Bone-anchored prostheses enhance quality of life but carry risks of mechanical failure.
• Sudden fracture can lead to falls and injuries, impacting user safety and confidence.

Purpose of the Study:

• To develop and evaluate an innovative protective component for bone-anchored prostheses.
• To mitigate risks associated with mechanical overload and prevent sudden prosthesis failure.
• To improve the safety, reliability, and user experience of bone-anchored prosthetic systems.

Main Methods:

• A protective element from Ti6Al4V alloy and a safety pin from ductile cast iron were designed.
• A 3D model was created using SolidWorks for numerical analysis.
• Simulations mimicked gait cycle phases (heel strike, toe-off) under critical loading conditions.

Main Results:

• The highest stress (248 MPa) occurred during toe-off with a safety factor of 1.6.
• Ductile cast iron proved suitable, offering controlled fracture under excessive load.
• Numerical analysis confirmed a high safety factor, indicating enhanced mechanical load resistance.

Conclusions:

• The novel protective system significantly improves the safety of bone-anchored prostheses.
• The design effectively minimizes injury risks from mechanical overload.
• This approach enhances user comfort, confidence, and overall quality of life.