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Innovative 3D-printed internal structure in silicone partial-hand prostheses: Enhancing function and mechanical
M Mohammad Zadeh1, M Jalali1, A Khaghani1
1Rehabilitation Research Center, Department of Orthotics and Prosthetics, School of Rehabilitation Sciences, Iran University of Medical Sciences, Tehran, Iran.
Canadian Prosthetics & Orthotics Journal
|July 1, 2026
Summary
This study introduces a novel 3D-printed silicone cosmetic prosthesis for partial hand amputation, significantly improving weight, stiffness, and user satisfaction. The new design enhances functional ability and durability compared to traditional prostheses.
Area of Science:
- Biomedical Engineering
- Materials Science
- Rehabilitation Medicine
Background:
- Silicone cosmetic prostheses aid body image for partial hand amputees but are often heavy and lack stiffness.
- Addressing these limitations is crucial for improving patient quality of life and prosthesis efficacy.
Purpose of the Study:
- To design and evaluate a novel silicone cosmetic prosthesis with a 3D-printed internal structure for improved lightweight and durability.
- To assess the impact of this new prosthesis on user satisfaction and functional ability.
Main Methods:
- A pilot study involving 7 participants with unilateral partial hand amputation.
- Fabrication of silicone prostheses with internal 3D-printed thermoplastic polyurethane (TPU) structures.
- Evaluation using TAPES (satisfaction) and DASH (function) questionnaires, alongside mechanical tests for stiffness and fatigue resistance.
Main Results:
- The 3D-printed TPU prosthesis was significantly lighter, stiffer, and more fatigue-resistant than conventional full-silicone prostheses.
- Participants reported superior functional ability (lower DASH scores) and higher satisfaction (TAPES scores) with the new prosthesis.
- Increased daily wear time was observed with the TPU-integrated prosthesis.
Conclusions:
- Silicone prostheses with 3D-printed internal TPU structures show promise for improved mechanical properties and functionality.
- This innovative design offers a potential advancement in cosmetic partial-hand prosthetics.
- Further research with larger sample sizes is recommended to validate these preliminary findings.
