A novel approach for improving material stiffness using a direct method in below-knee prosthetic sockets

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The conventional techniques for producing a socket are time-consuming disproportionate to the significant population afflicted by limb amputations. Although the new manufacturing direct method, the modular socket system (MSS) method, involves reduced labor time, the technique produces sockets with high stiffness that cause discomfort for those with lower limb amputations during walking. This study investigated the tensile characteristics of numerous materials in below-knee prosthetic sockets. Initially, a vacuum molding approach was used to produce the sockets, which involved various polymers and composite materials to improve the prosthesis socket properties. An F-socket device was also employed to ensure efficient production and optimized pressure distribution at the interface between the socket and the residual limb. A SOLIDWORKS® software was then applied to determine the numerical analysis (stress distribution and the maximum internal pressure). The samples from Group E involved utilizing a novel mixture compared to the direct and traditional methods of various materials. This study presents a novel prosthetic limb socket made from a mixture of four carbon fiber layers, utilizing 20% polyurethane resin and 80% acrylic as the matrix. The resulting material demonstrated acceptable stiffness, extended socket life, and reduced curing time. During the patient's gait cycle, peak pressure of 300 KPa was recorded using the F-socket, while SOLIDWORKS® software indicated an internal pressure of 343 KPa, aligning closely with F-socket measurements. The new direct-fit socket design prioritizes comfort and flexibility using materials with reduced stiffness.