Characterization of flexural and compressive behavior in polylactic acid composites for low‐cost transtibial prosthetic applications: Influence of reinforcements

Abstract

Loss of a lower limb leads to immobility, necessitating the use of prosthetic foot and socket as substitutes for lost limbs. However, the production of these prosthetic devices poses challenges due to the wide array of printing settings, materials, and post‐processing techniques involved. The objectives of this study were to examine the compression and flexural behavior of polylactic acid reinforced with carbon fiber fabricated via fused filament fabrication (FFF) and to investigate the effects of process constraints, namely nozzle hole diameter (0.20, 0.40, and 0.60 mm) and internal filling pattern (rectilinear, honeycomb, and triangle). The study employed compression and flexural tests, along with the analysis of failure morphology, on build samples. The resulting data were analyzed using Taguchi ANOVA and response surface methodology (RSM) to determine how compression and flexural behavior vary with the specified process constraints. The research findings demonstrate that the prosthetic socket and foot prosthesis created using FFF exhibit superior flexural and compressive behavior and strength, respectively. These results signify the potential for cost reduction in the production of prosthetic devices. The significance of these results lies in the improvement of prosthetic device production, enabling enhanced mobility and independence for amputees.