Bringing computational design and rapid prototyping to upper limb prosthetic socket design and manufacturing

Abstract

Advancements in additive manufacturing and computational design hold significant potential for expanding the variety of options available in upper limb prostheses. The primary objective of the thesis is to improve the overall user experience associated with 3D printed upper limb prosthetic sockets. This improvement is sought through the provision of personalized design optimization via topology optimization and the introduction of an innovative method to enhance comfort and functionality using cost-effective printing
equipment.

To achieve these research goals, the author adopted a research-through-design methodology, which included experimental prototyping. A modification design was developed to facilitate non-planar, rotating axis FDM printing with an affordable, commercially available 3D printer. Furthermore, a design workflow was established that optimizes the infill region and density to emulate muscle plasticity, thereby enabling personalized design without necessitating changes to the socket design. This approach entailed capturing a 3D scan of the user's
residual limb and applying topology optimization to the printed parts to identify areas requiring reinforcement.

Preliminary findings indicate that the non-planar rotating axis can improve the quality of parts in comparison to traditional configurations. Moreover, by incorporating personalized infill design through topology optimization, it is possible to reduce the weight of the socket while preserving its functionality. Secondary research suggests that this design methodology is likely to enhance user acceptance, improve quality of life, and decrease the likelihood of device abandonment.

The contributions of this research are poised to significantly enhance the accessibility of custom-fitted prosthetics, reducing reliance on healthcare providers and improving the quality of life for individuals dependent on prosthetic devices. Looking forward, the research will further to establish this integrated manufacturing process as the standard in the production of 3D-printed prosthetic devices, promoting innovation at the intersection of additive manufacturing and assistive technology

Date of Award	3 Sept 2024
Original language	English
Awarding Institution	Northumbria University
Supervisor	Sheng-feng Qin (Supervisor) & Raymond Oliver (Supervisor)