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<p>A stress-field-driven transfemoral prosthetic socket design was developed using functionally graded lattice structures and fabricated through a multi-material extrusion-based additive manufacturing process. Polyethylene terephthalate glycol (PETG) and thermoplastic polyurethane (TPU) were strategically assigned to the outer and inner regions of the socket, respectively, to achieve an optimal balance of structural rigidity and localized flexibility. Material and mechanical characterization of the individual polymers and their interface demonstrated intermediate mechanical behaviour at the PETG-TPU boundary. Spectral analysis revealed shifts in the carbonyl (−C=O) and urethane (−N−H) peaks, indicating intermolecular interactions and partial miscibility at the interface. Lattice configurations, including body-centered cubic (BCC) and gyroid structures, were evaluated with and without graded density variations. A radially graded gyroid lattice was selected based on its superior deformation response, with a 25&#xa0;mm cell size exhibiting approximately 1&#xa0;mm compression under a 950&#xa0;N load. The final socket demonstrated a maximum deformation of 6&#xa0;mm under a 400&#xa0;N mechanical load. These results demonstrate the effectiveness of integrating finite element-based stress mapping with digital design and multi-material fabrication in producing lightweight, anatomically conforming, and patient-specific prosthetic sockets.</p>

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Stress-field driven functionally graded lattice structures-based design and fabrication of transfemoral prosthetic socket using multi-material extrusion process

  • 期刊论文

  • 发表日期：

    2025年12月15日

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  • Mohit Teacher,
  • Rajkumar Velu,
  • Mayur Jiyalal Prajapati,
  • Jeng-Ywan Jeng

摘要

A stress-field-driven transfemoral prosthetic socket design was developed using functionally graded lattice structures and fabricated through a multi-material extrusion-based additive manufacturing process. Polyethylene terephthalate glycol (PETG) and thermoplastic polyurethane (TPU) were strategically assigned to the outer and inner regions of the socket, respectively, to achieve an optimal balance of structural rigidity and localized flexibility. Material and mechanical characterization of the individual polymers and their interface demonstrated intermediate mechanical behaviour at the PETG-TPU boundary. Spectral analysis revealed shifts in the carbonyl (−C=O) and urethane (−N−H) peaks, indicating intermolecular interactions and partial miscibility at the interface. Lattice configurations, including body-centered cubic (BCC) and gyroid structures, were evaluated with and without graded density variations. A radially graded gyroid lattice was selected based on its superior deformation response, with a 25 mm cell size exhibiting approximately 1 mm compression under a 950 N load. The final socket demonstrated a maximum deformation of 6 mm under a 400 N mechanical load. These results demonstrate the effectiveness of integrating finite element-based stress mapping with digital design and multi-material fabrication in producing lightweight, anatomically conforming, and patient-specific prosthetic sockets.