The standard traditional prosthetic pylon is manufactured from stainless steel, titanium, Aluminium alloys due to their lightweights. Despite the low weight of pylon made of these alloys, the pylon is characterized by its high costs. In this study, a new prosthetic pylon is designed and manufactured from PLA carbon fiber material to produce a pylon characteristic with a lighter weight and cheaper than the standard pylon with its ability to bear the patient’s weight without any mechanical failure. The mechanical properties (yield stress, ultimate stress, and endurance stress) of the PLA carbon fiber filament were measured. The finite element method analysis of the pylon was done by using the ANSYS-14.5 program. The experimental and numerical results showed that the weight of the new prosthetic pylon is less than the weights of Stainless steel, Titanium, and Aluminium pylon by 60%,42%, and 50%, respectively, and the cost of the new prosthetic pylon is cheaper than the Stainless steel, Titanium, and Aluminium pylon by 97.5%,98%, and 96%, respectively. The mechanical properties of printed pylon material are the modulus of elasticity equal to 1.38GPa, the yield stress is 33.5MPa, the ultimate stress is 49.14 MPa, and the endurance stress is 19.16 MPa. The results also showed that the pylon’s buckling stress is higher than the yield stress and von mises stress is less than the yield stress; this proves the successful design of the pylon. The new design is cheaper, lighter, and can withstand higher patient weights.