Additive manufacturing of a transtibial prosthetic socket through a FE-based topology optimization approach
Year: 2025
Type: article
Abstract: The present work explores the possibility of combining 3D printing and topology optimization to produce lightweight transtibial prosthetic sockets to reduce the manufacturing time, costs and material waste. Specifically, a topology optimization algorithm based on Finite Element (FE) method has been employed to determine the optimal material distribution for the prosthetic socket in Polyamide PA12. A FE analysis has been carried out to validate the behaviour of the optimized shape. Finally, the new shape has been 3D printed using the fused deposition modelling technology. Furthermore, a cost analysis has been performed on the 3D printed part and traditional prosthetic socket. The approach followed in the present work showed a time reduction of up to 50% for the production of the final prosthesis and a cost reduction of up to 80% compared to the traditional manufacturing process. Moreover, the optimization of the material distribution allows for a reduction of material use (i.e. −38%). This procedure demonstrates the potential of the proposed approach for developing an efficient and sustainable alternative in the manufacturing of prosthetic sockets. • An optimized transtibial prosthetic socket design was proposed using FE-based topology optimization. • Validation analysis confirmed the stress and displacement distributions of the optimized shape. • The optimized shape was 3D printed through FDM technique. • The proposed approach significantly reduces time and cost compared to traditional manufacturing.
Institutions: University of Chieti-Pescara, Marche Polytechnic University
Language: English
Subfield: Civil and Structural Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: hybrid
Estimated APC paid: $4,040
OpenAlex ID: W4414158437