Analysis and Fabrication of Functionally Graded Prosthetic Socket Using Fused Filament Fabrication

Abstract

Prosthetics are standard assistive devices that enable the partial movement of body parts lost due to dysvascular disorder or locomotive dysfunction. Conventionally fabricated prosthetics are stiff and lead to wounds and ulcers. As these devices require customization due to variations in the patient limb sizes, additive manufacturing (AM) provides an advantage in their fabrication. Therefore, it is necessary to design and develop a prosthetic socket from functional aspects. These aspects may be considered in two ways: graded from lattice structures and graded from polymer composites based on properties, such as deformation and elastic modulus. Simulation and analytical models optimize the modulus of elasticity and deformation corresponding to the material uses based on stiffness and flexibility. The gyroid-type lattice structures are used to provide lightweight and thermo-regulatory prosthetic sockets. However, the models become distorted due to the large size of STL files. Fused filament fabrication (FFF) of the AM technique fabricates the graded prosthetic socket based on the geometrical aspects. © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2025.