Propose Method for the Design of a Transtibial Prosthesis using Generative CAD/FEM Analysis and Additive Manufacturing

Prosthesis designers must deal with the constant cost problems for manufacturing a prosthesis for one person. A prosthesis is subjected to the body weight of people, especially when the person leans on the prosthesis. All the weight of the person falls on the limb that is attached to the prosthesis. Therefore, it is necessary to perform the static analysis of each piece to confirm that none of these will have break points and that mechanical displacements do not negatively influence the prosthesis. The aim of this project is the proposal of a method for the design and manufacture of prostheses based on six steps, among which digital design and additive manufacturing stand out. For this, a five-step method was used, starting with digital parameterization, generative design, finite element analysis, fabrication, and recycling of the prosthesis. Digital parameterization is the use of the scanner to create a mesh with which to design the coupling of the prosthesis. With the generative design, the measurements of the prosthesis were optimized, which were based on the scan of a stump and can support the weight of 225 lb. The h method to analyze the loads based on finite elements adapted the mesh to generate the best solution and guarantee the functioning of the prosthesis. The shapes developed by generative design were manufactured with additive manufacturing using ABS with a 100% fill. By using this method, it is guaranteed that the product can be recycled and use the raw material to generate new prostheses.