A new study by HP explores using 3D printing to advance prosthetic socket design, seeking to benchmark performance against traditionally manufactured carbon fiber sockets.
The emergence of additive manufacturing brings immense potential to customize and streamline prosthetic fabrication. However, comprehensive research comparing 3D-printed sockets is lacking. This investigation develops an innovative methodology to push the boundaries.
Partnering with prosthetic experts Quorum Prosthetics and Empirical Technologies, sockets were evaluated using both static and cyclic fatigue approaches. 3D printed on HP’s Multi Jet Fusion technology and durable HP 3D HR PA12 material, the prostheses were strained to induce failure limits.
Remarkably, the 3D-printed sockets withstood higher ultimate loads before breaking than the carbon fiber lay-up alternative. HP attributes this to the material’s flexible yet strong properties.
While carbon fiber fractured severely, HP 3D printed sockets failed more gracefully from baseplate attachments as pressure peaked. This suggests an opportunity to optimize connections for improved safety factors.
Cyclic fatigue assessments further demonstrated the printed prosthetics’ resilience as attachment points repeatedly gave out just prior to socket structure decline. By contrast, the carbon fiber socket showed substantial cracking over time from stress.
Leveraging robust FEA modeling techniques, HP also accurately simulated socket performance trends. This will inform future design iterations and customization capabilities.
Overall, the trials develop an equitable testing methodology for the industry while revealing advantages of HP 3D printing:
- Withstands higher static loads before failure
- Fails more safely compared to carbon fiber fracturing
- Delivers consistent results across prints
- Enables simulation for personalized optimizations
- Unlocks customization with highly repeatable properties
By pushing the boundaries of materials science and simulations, HP is committed to transforming prosthetics fabrication. 3D printing unlocks a future of limitless patient-matched design paired with unmatched quality, efficiency, and resilience.
