Topology Optimization of a 3D Printable Prosthetic Foot

This research tackles a novel prosthetic foot design, simulation and FDM (Fused Deposition Modeling) 3D printing by customizing it for a human of 50 kg body mass. An initial foot model was created in SolidWorks software using actual human foot dimensions and then topology optimization was applied to reduce mass by 70% while maintaining structural integrity under a 500 N external load and a factor of safety of 1.5. The three components of the stance phase-heelstrike, mid-stance, and toe-off-were simulated in a static manner utilizing force on the tibia. The results showed stress levels below the yield strength, confirming the foot’s capacity to sustain body weight while standing without failing. Using PLA (Polylactic acid) material, the revised and optimized design was manufactured using a Creality Ender-3 S1 Plus 3D printer. The prosthetic foot weighed 564 grams and had 60% infill after 3D printing. The effectiveness of optimization process is demonstrated by the notable mass reduction from the $2.34 \mathbf{~ k g}$ mass of the original design model. The PLA material qualities are taken into account in the computations and simulations. This prosthetic foot is a financially sensible option, as indicated by its computed cost of about 5,574 Taka. The presented design shows a significant percentage reduction of material as well as cost in comparison to the commercially available prosthetic feet.