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Home Clinical Issues

Developing an Innovative Amputated Limb Simulator to Advance Clinicians’ Skills

by Christopher Hovorka PhD, CPO, FAAOP
February 1, 2026
in Clinical Issues
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Two million people are living with limb loss in the United States and more than 550,000 new amputations occur annually, 50 percent of which involve the lower limb at the transtibial level.1-3 Most people acquire transtibial amputations from complications of diabetes and vascular disease, which renders the residual limb vulnerable to tissue damage when the limb experiences high forces, particularly during weight bearing activities such as standing, walking, etc.3 This is a concern because the socket of a lower-limb prosthesis is the critical point of force transfer at the residuum and is a major contributor to a prosthesis user’s experiences, quality of life, and clinical outcomes.4-7

Appropriate socket fit requires clinicians to accurately capture the shape of the residuum. These methods are usually taught by utilizing expensive and variable patient-model learning experiences.8 Due to budget and time constraints, educational programs expose students to patient models a few times per course, and they have limited skills practice prior to clinical residency.9 Simulation-based training can help students develop skills before they practice on real patients and increase the opportunity to practice these skills independent of a patient model.10-12 Unfortunately, there is a lack of high-fidelity simulation-based training and an absence of quantified evidence in learning outcomes associated with it in O&P training programs.

To address this gap, a team of clinicians and researchers led by Christopher Hovorka, PhD, CPO, FAAOP, assistant professor at Baylor College of Medicine’s Orthotics and Prosthetics Program, in collaboration with Marcia O’Malley, PhD, director of Rice University’s Mechatronics and Haptic Interfaces Lab, is developing a novel amputated limb simulator with a force-feedback system to enhance clinicians’ skills in prosthetics. The project received funding from multiple agencies including the Huffington Department of Education Innovation and Technology, the Orthotics & Prosthetics Foundation for Education and Research, and the Texas Society of Allied Health Professions. The Rice team will embed an array of force-sensing resistors onto a simulator that replicates a limb with a transtibial amputation. The limb simulator is composed of a silicone matrix and rigid plastic skeletal, and elastic connective tissue structures that emulate the anatomical structures of a conical-shaped amputated limb (Figures 1 and 2). When learners palpate the simulated limb with their hands, a visual display of the limb will include a force profile and wrist vibration to inform their performance of the magnitude and location of force applied to the limb (Figure 3). The system uses low-cost sensors that collect the forces applied to the limb, a graphical user interface projecting the force feedback, and wrist bracelet vibration to inform learners whether the force imposed is within or exceeds a safe threshold.

FIGURE 1 Sagittal view of the transtibial amputated limb simulator. (A) The limb simulator depicting the underlying rigid plastic skeletal structures. The limb simulator is anchored to a pipe and clamp sleeve that are inserted into a vice (red). (B) A clinician demonstrating compression of the silicone at the distal end of the limb simulator.
FIGURE 2 Coronal view of the transtibial amputated limb simulator. (A) The amputated limb simulator attached to a vice. (B) A clinician demonstrating a palpation procedure on the amputated limb simulator.

 

 

 

 

 

 

 

 

 

 

 

 

FIGURE 3 Illustration of the novel amputated limb simulator with low-cost force sensors imbedded at the surface (blue solid circles). Force feedback is provided visually on a laptop and wrist vibration informs the learner whether the applied force is unsafe (e.g., exceeds the target force, depicted in red) or is safe (e.g., within a target force threshold depicted in green).

The Baylor team will evaluate the fidelity of the feedback system and determine the optimal force threshold for feedback. Then the team will evaluate learners’ clinical skills performance before and after participation in a simulation-based training protocol. The goal of the novel force-feedback system and the simulation-based training protocol is to enable students to make errors and informed corrections that reinforce skill acquisition and learning.12-15 The team at Baylor will evaluate the simulator’s effectiveness to reinforce entry-level student skills in palpation of anatomical landmarks, measurement of limb dimension, and residual-limb shape capture—all essential clinical procedures that determine prosthetic socket fit.

The use of the simulator and the simulation-based training module has the potential to reduce costs and enable student performance in skills that influence clinical outcomes, patient experiences, and quality of life, which are key priorities that align with patient-oriented and values-based care initiatives in US healthcare. The proposed force-feedback system is an advantage over rudimentary amputated limb simulators that are infrequently used for prosthetist training. These rudimentary systems lack a feedback system to inform learners’ performance, which is essential for developing clinical skills.

Significance

Anecdotal reports suggest the use of an amputated limb simulator for skills practice prior to students engaging in patient model learning experiences may enhance student self-confidence.16 However, it is unknown if student use of the amputated limb simulator translates to improved student performance related to prosthetic socket fit. Additionally, there are several skills that contribute to socket fit, such as identification of anatomical landmarks, limb measurement, and impression taking. Evaluating the acquisition of these skills and the associated outcomes may improve our understanding of the value of simulation-based training in prosthetics.

Hence, the lack of simulation-based training in prosthetics provides an opportunity for developing and evaluating an innovative force-feedback simulator technology to enhance student learning of important clinical skills. This has the potential to provide new knowledge on the utility and effectiveness of a force-feedback system as a teaching tool to advance clinicians’ skills and performance. Specifically, there are two areas of potential impact. First there is opportunity to clarify the optimal force thresholds for safe palpation, measurement, and impression taking as these are currently unknown. Knowledge in this area can inform teaching strategies and learner assessment across all levels of clinician training (e.g., primary entry-level foundational training, residency training, and post-certification continuing education skills assessment). Second, the novel force-feedback simulator has the potential to advance instructional methods for high-stakes clinician skills training by serving as a tool for repeated task practice prior to student engagement with patient models. As such, it could improve the student and patient model learning experience by reinforcing student confidence and skills and reducing errors and harm to patient models.

More broadly, the potential benefits of the novel simulator as a teaching tool are in its measurement capabilities, which can improve our understanding of student learning of complex clinical skills and how these skills translate to improving prosthetic socket fit, patient health, and quality of life.

Christopher Hovorka, PhD, CPO, FAAOP, is an educator and scientist in Baylor College of Medicine’s Orthotics and Prosthetics Program. After a career as an exercise physiologist, he pivoted into O&P first by completing a bachelor’s degree in O&P at the University of Washington and residencies in orthotics (Southern Illinois University School of Medicine) and prosthetics (Connecticut Children’s Medical Center). After several years of clinical practice in O&P and a desire to advance clinician education and evidence to support clinical decision making, he pursued graduate degrees in allied health science (Master of Science at the University of Connecticut) and a doctorate in applied physiology/motor control at Georgia Tech. As an educator and scientist, he was awarded 34 research and development grants, produced 24 peer-reviewed publications, received nearly a dozen national educator excellence awards, developed 101 courses, and taught 51 courses. He is now applying what he has learned in his research and teaching experience to advance health professions education through course instruction and development of simulation-based training for O&P clinical skills reinforcement and competency assessment. He can be reached at chris.hovorka@bcm.edu.

Acknowledgement

The author acknowledges Juan Guzman, business operations coordinator, Baylor College of Medicine Orthotics & Prosthetics, who was instrumental in the photo and video capture and editing for this article and more material that will be used in a simulation-based training program. The program, currently in development, will instruct learners on clinical methods using the amputated limb simulator that are performed in an effective and reproducible manner.

From left: Chris Hovorka, PhD, CPO, FAAOP, project lead; Ashley Mullen, PhD, MSAT, CPO, O&P program lead; Amandi Rhett, course lead; Jeremy Sherman, curriculum lead; Claudia Archer, O&P student; Stefany Crosby, O&P student; Juan Guzman, business operations coordinator; Marcia O’Malley, PhD, lab lead; Shane King, PhD, haptics lead; Mary Herman, doctoral student.

References

  1. American Board for Certification in Orthotics, Prosthetics and Pedorthics Inc. 2022.
  2. Rivera, J. A., K. Churovich, A. B. Anderson, and B. K. Potter. 2024. Estimating recent U.S. limb loss prevalence and updating future projections. Archives of Rehabilitation Research and Clinical Translation 6(4):100376.
  3. Zigler-Graham, K., E. J. MacKenzie, P. L. Ephraim, T. G. Travison, and R. Brookmeyer. 2008. Estimating the prevalence of limb loss in the U.S.: 2005 to 2050. Archives of Physical Medicine and Rehabilitation 89(3):422-9.
  4. Armitage, L., K. A. McDonald, L. Kark, A. Buller, and B. Ford. 2023. Transtibial prosthetic socket fitting: Australian prosthetist perspectives on primary challenges, management strategies, and opportunities for workflow and technological innovation. Prosthetics and Orthotics International 47(2):194-203.
  5. Larson, B. G., K. J. Allyn, M. A. Ciol, and J. E. Sanders. 2021. Performance of a sensor to monitor socket fit: Comparison with practitioner clinical assessment. Journal of Prosthetics and Orthotics. 33(1):3-10.
  6. Turner, S., and A. H. 2020. Perceived effect of socket fit on major lower limb prosthetic rehabilitation: A clinician and amputee perspective. Archives of Rehabilitation Research and Clinical Translation 2(3):100059.
  7. Won, N. Y., M. Garibaldi, and R. E. Baumgartner, et al. 2022. Scoping review to evaluate existing measurement parameters and clinical outcomes of transtibial prosthetic alignment and socket fit. Prosthetics and Orthotics International 46(2):95-107.
  8. National Commission on Orthotic and Prosthetic Education (NCOPE) Core Curriculum Guide (Master’s Curriculum Standards) for Practitioner Education. Alexandria, VA; 2017.
  9. Koger, G. F., and C. F. Hovorka. 2021. Academia’s role to drive change in the orthotics and prosthetics profession. Canadian Prosthetics and Orthotics Journal 4(2):21:1-7.
  10. Hammoud, M. M., F. S. Nuthalapaty, and A. R. , et al. 2008. To the point: medical education review of the role of simulators in surgical training. American Journal of Obstetrics and Gynecology 199(4), 338-43.
  11. Elendu, C., D. C. Amaechi, and A. U. Okatta, et al. 2024. The impact of simulation-based training in medical education: A review. Medicine 103(27), e38813.
  12. Scerbo, M. W., E. A. Schmidt, and J. P. Bliss. 2006. Comparison of a virtual reality simulator and simulated limbs for phlebotomy training. Journal of Infusion Nursing 29(4):214-224.
  13. Hagemann,E. 2009. Role of simulation in rehabilitation: Effectiveness of model hands when learning to make orthoses. Master’s Thesis. University of Toronto.
  14. Heskin, L., R. Galvin, O. Traynor, and C. Simms. 2022. Simulation in upper and lower limb trauma skill acquisition: A review. Simulation in Healthcare : A Journal of the Society for Simulation in Healthcare 17(1):54-65.
  15. Pei, Y., M. Mansouri, C. M. Zallek, and E. T. Hsiao-Wecksler. 2023. Modeling, control, and clinical validation of an upper-limb medical education task trainer for elbow spasticity and rigidity assessment. IEEE Transactions on Neural Systems and Rehabiiltation Engineering 31:3320-30.
  16. Hockey, S. Personal communications from March 2022 to September 2023 with Stephen Hockey, Prosthetics and Orthotics Program, LaTrobe University, Melbourne, New South Wales, Australia.

 

 

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