Researchers at Simon Fraser University, British Columbia, Canada, combined personalized pressure mapping and a lighter infill to create a more customized prosthesis that can be worn comfortably for much longer than traditional sockets. They found that their 3D-printed socket design absorbed 1,600 percent more energy when the user was standing compared to a traditional solid-infill socket, and 1,290 percent more energy when walking.
“For the first time, this 3D-printing technology is capturing unique pressure and force distribution data from a patient and using that data to design a custom prosthetic device and fabricate a much lighter, more breathable, and pressure-responsive socket,” said Woo Soo Kim, PhD, a professor at the university’s School of Mechatronic Systems Engineering and corresponding author of a study about the development.
Traditional prosthetic devices are very precise in terms of measurements and shape, but don’t account for individualized pressure points and force distribution unique to each person, Kim said.
For the study, the researchers embedded a silicone liner with a miniature 3D-printed pressure sensing mat that had a network of origami sensors to measure pressure and force. The test patient wore the pressure mapping liner inside a temporary socket while standing, walking on a flat surface, walking down a ramp, and leaning left and right to mimic everyday activity.
Customized software used artificial intelligence (AI) to translate the data into a personalized 3D-printed socket design using a custom gyroid lattice structure—a highly organized, repeating 3D pattern often found in nature and biology, like a honeycomb or the inside structure of human bone.
Kim said the streamlined fabrication of a pressure map liner, AI-assisted design optimization software, and 3D-printed socket technology could revolutionize prosthetics design.
Hodgson Group Orthotics and Prosthetics, British Columbia, Canada, participated in the research to help bridge clinical practice with emerging technology in a way that directly benefits people with limb loss.
Being involved in the development and evaluation of the 3D-printed pressure-mapping system has highlighted how “data-driven design can meaningfully improve prosthetic fit, comfort, and long-term skin health—areas that have challenged our profession for decades,” said Loren Schubert, CP(c), Hodgson Group.
“This work demonstrates how innovative, customizable, and more cost-effective solutions can reshape the future of prosthetic liners and sockets, ultimately expanding access and improving the everyday experience of patients,” added Carl Ganzert, CO(c), Hodgson Group.
Aside from benefits for prosthesis users, the researchers said the sockets may also reduce common complications like ulcers, pain, instability, musculoskeletal issues, and osteoarthritis by absorbing more energy.
Editor’s note: This story was adapted from materials provided by Simon Fraser University.
The open-access study, “Streamlined custom manufacturing for optimized 3D printed prostheses through 3D pressure mapping,” was published in Biosensors and Bioelectronics.
