Design Evaluation of FFF-Printed Transtibial Prosthetic Sockets Using Follow-Up and Finite Element Analysis

Abstract

Background: Participants in Sierra Leone received a Fused Filament Fabrication (FFF)-printed transtibial prosthetic socket. Follow-up was conducted on this group over a period of 21 months. To investigate the failure of some of the FFF-printed transtibial sockets, further strength investigation is desired. Methods: A finite element (FE) analysis provided an extensive overview of the strength of the socket. Using follow-up data and FE analyses, weak spots were identified, and the required optimization/reinforcement of the socket wall was determined. Results: Five sockets with a 4 mm wall thickness were tested by five participants. The strength of the 4 mm prosthetic socket seemed to be sufficient for people with limited activity. The 4 mm sockets used by active participants failed at the patella tendon or popliteal area. One socket with a wall thickness of 6 mm was used by an active user and remained intact after one year of use. An FE analysis of the socket showed high stresses in the patella tendon area. An increased wall thickness of 7 mm leads to a decrease of 26% in the stress corresponding to the observed failure in the patella tendon area, compared to the 4 mm socket. Conclusions: Follow-up in combination with an FE analysis can provide insight into the strength of the transtibial socket. In future designs, both the patella tendon and popliteal area will be reinforced by a thickened trim line of 7 mm. A design with a thickened trimline of 7 mm is expected to be sufficiently strong for active users. Another follow-up study will be performed to confirm this.

Overcoming Challenges and Innovations in Orthopedic Prosthesis Design: An Interdisciplinary Perspective

“…Interdisciplinary collaboration is becoming increasingly important in the field of orthopedic prosthesis design [ 52 ]. By bringing together experts from various disciplines such as materials science, biomechanics, medicine, and engineering, it is possible to develop more effective solutions that address the complex challenges of orthopedic prosthesis design [ 53 ]. For example, collaborations between medical professionals, material scientists, and engineers can lead to the development of advanced materials that are more biocompatible and durable, as well as improved surgical techniques for attaching prosthetics to natural bones and tissues [ 54 ].…”

3D printing in biomedicine: advancing personalized care through additive manufacturing

“…These innovative technologies hold significant potential for elevating the capabilities of orthopedic prostheses. Realizing the full potential of these nextgeneration orthopedic prostheses entails addressing critical factors such as fostering interdisciplinary collaboration among experts in orthopedics, materials science, biology, and engineering, increasing investments in research and development, standardizing components to ensure quality and reliability, and improving accessibility to prosthetic solutions [101].…”

“…The impact of these challenges on 3D printed medical devices and implants is profound, potentially leading to adverse outcomes, regulatory complexities, and ongoing material safety research efforts. Manufacturers must prioritize robust research on material biocompatibility, adherence to stringent testing protocols, and vigilant monitoring of emerging concerns related to materials to ensure the safety and efficacy of these transformative healthcare innovations [101].…”

Dental implant survival in epidermolysis bullosa patients: A systematic review conducted according to PRISMA guidelines and the Cochrane handbook for systematic reviews of interventions

“…It underscores the importance of comprehensive care and collaboration among different healthcare specialists in managing the overall well-being of individuals with complex medical conditions. Although results reported in children and teenagers, primarily when implants were placed in the maxilla or the symphyseal region of the anterior mandible, have been less encouraging, most series show an excellent implant success rate in adults with ectodermal dysplasia [ [28] , [29] , [30] , [31] , [32] ]. There is still debate over when dental implants should be placed in developing toddlers.…”