Integration of EMG and Machine Learning for Real-Time Control of a 3D-Printed Prosthetic Arm

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Background: Advancements in low-cost additive manufacturing and artificial intelligence have enabled new avenues for developing accessible myoelectric prostheses. However, achieving reliable real-time control and ensuring mechanical durability remain significant challenges, particularly for affordable systems designed for resource-constrained settings. Objective: This study aimed to design and validate a low-cost, 3D-printed prosthetic arm that integrates single-channel electromyography (EMG) sensing with machine learning for real-time gesture classification. The device incorporates an anatomically inspired structure with 14 passive mechanical degrees of freedom (DOF) and 5 actively actuated tendon-driven DOF. The objective was to evaluate the system’s ability to recognize open, close, and power-grip gestures and to assess its functional grasping performance. Method: A Fast Fourier Transform (FFT)-based feature extraction pipeline was implemented on single-channel EMG data collected from able-bodied participants. A Support Vector Machine (SVM) classifier was trained on 5000 EMG samples to distinguish three gesture classes and benchmarked against alternative models. Mechanical performance was assessed through power-grip evaluation, while material feasibility was examined using PLA-based 3D-printed components. No amputee trials or long-term durability tests were conducted in this phase. Results: The SVM classifier achieved 92.7% accuracy, outperforming K-Nearest Neighbors and Artificial Neural Networks. The prosthetic hand demonstrated a 96.4% power-grip success rate, confirming stable grasping performance despite its simplified tendon-driven actuation. Limitations include the reliance on single-channel EMG, testing restricted to able-bodied subjects, and the absence of dynamic loading or long-term mechanical reliability assessments, which collectively limit clinical generalizability. Overall, the findings confirm the technical feasibility of integrating low-cost EMG sensing, machine learning, and 3D printing for real-time prosthetic control while emphasizing the need for expanded biomechanical testing and amputee-specific validation prior to clinical application.

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