Development and testing of thermoplastic structural components for modular prostheses

A systematic review of methods used to assist transtibial prosthetic alignment decision-making

Prosthetic alignment is a highly subjective process that is still based on clinical judgments. Thus, researchers have aimed their effort to quantify prosthetic alignment by providing an objective method that can assist and guide prosthetists in achieving transtibial (TT) prosthetic alignment. This systematic review aimed to examine the current literature on TT prosthetic alignment to scope the qualitative and quantitative methods designed to guide prosthetists throughout the TT prosthetic alignment process as well as evaluate the reported instruments and devices that are used to align TT prostheses and their clinical feasibility. A literature search, completed in June 2022, was performed using the following databases: Web of Science (Clarivate), SCOPUS (Elsevier), and Pub Med (Medline) with searching terms focusing on TT, prosthesis, prosthetist, prosthetic alignment, and questionnaires, resulting in 2790 studies being screened. Twenty-four studies have used quantitative methodologies, where sensor technologies were found to be the most frequently proposed technology combined with gait analysis tools and/or subjective assessments. A qualitative method that assists prosthetists throughout the alignment process was not found. In this systematic review, we presented diverse methods for guiding and assisting clinical decision-making regarding TT prosthetic alignment. However, most of these methods considered varied parameters, and there is a need for elaboration toward standardized methods, which would improve the prosthetic alignment clinical outcome.

Numerical simulation and experimental testing for static failure prediction in additively manufactured below-knee prosthetic sockets

The socket of a transtibial prosthesis is a structural part customized to a patient's amputated residual lower limb. The free-form geometry of the socket can be suitable for additive manufacturing (AM) to save time and cost. However, the mechanical fracture of additively manufactured lower limb prostheses is not yet fully understood. A novel experimental method and numerical approach by finite element method (FEM) to test the strength and fracture behavior of a lower limb prosthetic socket of acrylonitrile butadiene styrene (ABS), reverse-engineered using computer-aided design (CAD) from the actual amputee's residual limb and manufactured using fused filament fabrication (FFF) are proposed in the present work. The mechanical behavior, von Mises stress distribution, and the damage status of layered AM sockets of different thicknesses were simulated by FEM using Hashin's transversely isotropic mechanical damage model, initially developed for composite materials. The experimental work showed that the fracture failure initiated at the corner of the lobe in the 4 mm thickness socket at a failure load of 918.5 N. The FEM results predicted this failure load to be 896.6 N, with only a 2.45% error as compared to the experiment. The failure loads predicted by FEM in the sockets with thicknesses of 3, 5, and 6 mm were 618.1, 1008.6, and 1105.2 N, respectively. The present work provides a dependable method for testing a below-knee prosthetic socket against static failure and arriving at a factor-of-safety (FoS) based socket thickness selection for any amputee.

Static strength of lower-limb prosthetic sockets: an exploratory study on the influence of stratigraphy, distal adapter and lamination resin

Knowledge about the mechanical properties of lower-limb prosthetic sockets fabricated with resin infusion lamination and composite materials is limited. Therefore, sockets can be subject to mechanical failure and over-dimensioning, both of which can have severe consequences for patients. For this reason, an exploratory study was conducted to analyze the effect of stratigraphy (layup and fibers), matrix (resin) and mechanical connection (socket distal adapter) on socket static strength, with the objectives of: 1) implementing a mechanical testing system for lower-limb prosthetic sockets based on ISO 10328:2016 and provide the mechanical design of the loading plates, 2) apply the testing system to a series of laminated sockets, and 3) for each type of distal adapter, identify the combinations of stratigraphy and matrix with acceptable strength and minimum weight. Twenty-three laminated sockets were produced and tested. Sixteen met the required strength, with ten exhibiting an excessive weight. Among the remaining six, four combinations of stratigraphy and resin were identified as best option, as they all overcame ISO 10328 P6 loading level and weighted less than 600 g. The selected stratigraphies had limited or absent amount of Perlon stockinettes, which seems to increase weight without enhancing the mechanical strength. Sockets based on Ossur MSS braids and connector show the best compromise between strength and weight when the amount of carbon braids is halved.

Mechanical testing of transtibial prosthetic sockets: A discussion paper from the American Orthotic and Prosthetic Association Socket Guidance Workgroup

BACKGROUND

The advent of novel manufacturing technologies, materials, and socket design concepts could introduce risks to prosthetic limb users, as the existing knowledge base for safe fabrication may not apply. Moreover, although structural test standards exist for mass-produced prosthetic components, they are not applicable to prosthetic sockets.

METHODS

The "AOPA Socket Guidance Workgroup" was formed in 2020 to provide the prosthetic community with evidence-based clinical best practices and methods in the field of prosthetic socket structural analysis. This multidisciplinary expert workgroup undertook a critical analysis of the knowledge gaps regarding the requirements for mechanical testing of lower limb prosthetic sockets.

RESULTS

The Workgroup identified knowledge gaps in 4 domains. Domain 1 describes the shape and composition of a mock residual limb, required to support and generate in vivo representative loading within the socket. Domain 2 concerns prosthetic socket coordinate systems and alignment. Domain 3 regards the components and requirements of test specimens. Finally, Domain 4 considers test conditions, loading parameters, and acceptance criteria.

CONCLUSIONS

This paper describes these knowledge gaps in detail and recommends potential solution approaches based on literature review, group consensus around existing knowledge, or the formation of new study groups to fill each knowledge gap. Our intent is for the recommendations arising from this paper to support the community (e.g., researchers in the clinic, academia, industry, and funders) in addressing these knowledge gaps.

Parametric study of orthopedic insole of valgus foot on partial foot amputation

Orthopedic insole was important for partial foot amputation (PFA) to achieve foot balance and avoid foot deformity. The inapposite insole orthosis was thought to be one of the risk factors of reamputation for foot valgus patient, but biomechanical effects of internal tissues on valgus foot had not been clearly addressed. In this study, plantar pressure on heel and metatarsal regions of PFA was measured using F-Scan. The three-dimensional finite element (FE) model of partial foot evaluated different medial wedge angles (MWAs) (0.0°-10.0°) of orthopedic insole on valgus foot. The effect of orthopedic insole on the internal bone stress, the medial ligament tension of ankle, plantar fascia tension, and plantar pressure was investigated. Plantar pressure on medial heel region was about 2.5 times higher than that of lateral region based on the F-Scan measurements. FE-predicted results showed that the tension of medial ankle ligaments was the lowest, and the plantar pressure was redistributed around the heel, the first metatarsal, and the lateral longitudinal arch regions when MWA of orthopedic insole ranged from 7.5° to 8.0°. The plantar fascias maintained about 3.5% of the total load bearing on foot. However, the internal stresses from foot bones increased. The simulation in this study would provide the suggestion of guiding optimal design of orthopedic insole and therapeutic planning to pedorthist.

Fatigue test of low-cost flexible-shank monolimb trans-tibial prosthesis

Monolimb refers to a kind of trans-tibial prostheses with the socket and shank moulded into one piece of thermoplastic material. If properly designed, the shank of a monolimb can deflect which may compensate for the lost ankle plantarflexion and dorsiflexion to some extent. However, provision of shank flexibility is usually accompanied by reduced structural strength of the entire prosthesis. In the recent work using finite element analysis and the Taguchi method, the dimensions of the shank for the monolimb were derived which aimed at giving high shank flexibility and reasonable strength to resist static load. Yet, fatigue testing has not been performed. Fatigue failure may happen when a relatively low level of load is applied repeatedly. This study aimed to document the fatigue life of two flexible-shank monolimbs, by applying cyclic force of 800 N at the forefoot region for 500,000 cycles. Results showed that the design of the foot bolt adaptor played an important role in the structural integrity of the monolimb. One monolimb completed the fatigue test of 500,000 cycles without visual material yield, but with 3.8 degrees change in dorsiflexion angle when the load was removed.

Static structural testing of trans-tibial composite sockets

The purpose of this investigation was to quantify the structural strength of various trans-tibial composite sockets. To conduct the study, loading parameters and methods were developed that emulate the International Standards Organisation (ISO) standards for structural testing of lower limb prostheses since specific guidelines for the testing of the trans-tibial socket portion of a prosthesis have not yet been established. The experimental set-up simulated the instant of maximum loading during the late stance phase of gait. Ten trans-tibial sockets were evaluated. Five different reinforcement materials and two resin types were used to construct the sockets. A standard four hole distal attachment plate was used to connect the socket and pylon. Each sample was loaded to failure in a servo-hydraulic materials test machine at 100 N/s. None of the composites in the study met the ISO 10328 standards for level A100, loading condition II (4025 N), as required for other prosthetic componentry. All failures occurred at the site of the pyramid attachment plate. Ultimate strength and failure type were material dependent. Load point deflection was significantly different for the resin variable (p<0.05). Statistical differences according to reinforcement material were noted in composite weight and strength-to-weight ratio (p<0.05). The fibre volume fraction was also estimated and recorded. Reinforcement material type was the primary determinant of performance for the tested samples. Carbon reinforcements performed better than fibreglass reinforcements of similar weave type. The greatest ultimate strength and strength-to-weight ratio was observed with the unidirectional carbon reinforcement.