Abstract

This paper presents the results of experiments conducted on a batch of additively manufactured customized prosthetic sockets for upper limbs, made of thermoplastics and designed automatically on the basis of a 3D-scanned limb of a 3-year-old patient. The aim of this work was to compare sockets made of two different materials—rigid PLA and elastic TPE. Two distinct socket designs with various mounting systems were prepared. To find a reliable set of parameters for cheap and stable manufacturing of usable prostheses using 3D printers, realizing the fused deposition modeling (FDM) process, sets of sockets were manufactured with various process parameters. This paper presents the methodology of the design, the plan of the experiments and the obtained results in terms of process stability, fit and assessment by patient, as well as strength of the obtained sockets and their measured surface roughness. The results are promising, as most of the obtained products fulfil the strength criteria, although not all of them meet the fitting and use comfort criteria. As a result, recommendations of materials and process parameters were determined. These parameters were included in a prototype of the automated design and production system developed by the authors, and prostheses for several other patients were manufactured.

Highlights

  • The manufacturing was realized according to the plan and obtained a complete set of prosthetic sockets

  • The highest deviation is for the vacuum socket made of elastic thermoplastic polyester (TPE) material

  • The lowest is for the Velcro-fastened socket made of more rigid Polylactic acid (PLA)

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Summary

Introduction

Additive manufacturing has been successfully used for many years, for the production of prototypes [3], and of final products or their parts [4]. The scientific literature is full of examples of attempts to implement additive manufacturing methods in medicine. The common feature of the vast majority of these examples is the uniqueness of the geometry produced, tailored to the needs of a particular patient or medic. The medical applications of additively produced elements can be divided into several areas: bioprinting (tissue and organ production) [5], prosthetic and orthopedic equipment [6], teaching aids, pre- and intraoperative supplies [7]

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