Different tasks and conditions in gait call for different stiffness of prosthetic foot devices. The following work presents a case study on design modifications of a prosthetic foot, aimed at variable stiffness of the device. The objective is a proof-of-concept, achieved by simulating the modifications using finite element modeling. Design changes include the addition of a controlled damping element, connected both in parallel and series to a system of springs. The aim is to change the stiffness of the device under dynamic loading, by applying a high damping constant, approaching force coupling for the given boundary conditions. The dynamic modelling simulates mechanical test methods used to measure load response in full roll-over of prosthetic feet. Activation of the element during loading of the foot justifies the damped effect. As damping is in contrast to the main design objectives of energy return in prosthetic feet, it is considered important to quantify the dissipated energy in such an element. Our design case shows that the introduction of a damping element, with a high damping constant, can increase the overall rotational stiffness of the device by 50%. Given a large enough damping coefficient, the energy dissipation in the active element is about 20% of maximum strain energy.

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The key goal of prosthetic foot design is to mimic the function of the lost limb. A passive spring and damper system can imitate the behavior of an ankle for low level activity, e.g. walking at slow to normal speeds and relatively gentle ascents/descents. In light of this, a variety of constant stiffness prosthetic feet are available on the market that serve their users well. However, when walking at a faster pace and ascending/descending stairs, the function of the physiological ankle is more complex and the muscular activity contributes to the stride in different ways. One of the challenges in prosthetic device design is to achieve the appropriate range of stiffness of the arrangement of joints and spring elements for different tasks, as well as varying loading of the prosthetic device. This calls for an adaptive mechanism that mimics the stiffness characteristics of a physiological foot by applying real-time adaptive control that changes the stiffness reactively according to user’s needs. The goal of this paper is to define the stiffness characteristics of such a device through modeling. The research is based on a finite element model of a well-received prosthetic foot design, which is validated by mechanical measurements of the actual product. We further enhance the model to include a secondary spring/dampener element. Various smart material technologies are considered in the design to provide control of flexibility and damping rate of the ankle joint movement. The reactive control of the secondary element allows the simulated prosthetic foot to adapt the ankle joint to imitate the behavior of the physiological ankle during different activities and in different phases of the gait cycle.

The unique rheological properties of discontinuously shear thickening fluids (STF) have been employed in various engineering applications in recent years. In a commercial aspect, this has most notably been body armor and protective equipment, but also specialized smart structures in damping and force-coupling applications. The topic of this work is the application of STF in an articulating prosthetic foot for adaptable force response. Connected in series and parallel to a spring system, a STF based element can be used to affect the force transfer within the system, and thereby, influence the stiffness of the prosthetic foot dynamically over the gait cycle. The device described, prototyped and tested in this work, is a STF filled piston/cylinder design. The objective is a velocity dependent force response over the translational motion. Ranging from dampened, compliant deflection at low velocity, to a more efficient force transfer (coupling) for energy storage and return in the spring system, at higher speed. The rapid viscosity increase in the STF at a critical shear rate is used to approach a stepwise force response, thereby enabling adaptive response of the foot for different load rates. The adaptive response results in a greater range of motion with easier rollover for slow movement, for instance standing up from a seated position and adaptation to inclined surfaces, without sacrificing the energy return favorable for normal walking.

Energy-storing-and-returning prosthetic feet are frequently recommended for lower limb amputees. Functional performance and stiffness characteristics are evaluated by state-of-the-art biomechanical testing, while it is common practice for design engineers and researchers to use test machines to measure stiffness. The correlation between user-specific biomechanical measures and machine evaluation has not been thoroughly investigated, and mechanical testing for ramps is limited. In this paper, we propose a novel test method to assess prosthetic foot stiffness properties in the sagittal plane. First, biomechanical data were collected on five trans-tibial users using a variable stiffness prosthetic foot on a split-belt treadmill. Gait trials were performed on level ground and on an incline and a decline of 7.5°. The same prosthetic foot was tested on a roll-over test machine for the three terrains. The sagittal ankle moment and angle were compared for the two test methods. The dorsiflexion moment and angle were similar, while more variability was observed in the plantarflexion results. A good correlation was found for level-ground walking, while decline walking showed the largest differences in the results of the maximum angles. The roll-over test machine is a useful tool to speed up design iterations with a set design goal prior to user testing.