Achieving New Standards in Prosthetic Socket Manufacturing

Sammanfattning: Preface: The research about product development of a prosthetic socket was conducted by two students from Mälardalen University, department of Innovation, Design, and Technology. Background: The most recent public survey shows that an estimated 5 million people in China are amputees, out of which a significantly large portion are below-elbow amputees. Sockets sold to below-elbow amputees are equipped with only two surface electromyography sensors, has low comfortability, has problems with perspiration, and a high weight. The current standard for socket manufacturing has not changed in decades. Research Questions: The following research questions have determined the direction of the research: (1) What measurable factors contribute to a convenient and ergonomic feature design in prosthetic socket from the end-user’s perspective? (2) How can the weight and functionality be improved to achieve a prosthetic socket more suited to the end-user, with respect to the existing prosthetic socket? (3) Which material and manufacturing method is suitable for producing cost-effective and customized prosthetic sockets? Research Method: The research was guided by the 5th edition of Product Design and Development by Ulrich & Eppinger (2012) where the product development process described in five of the six phases from planning to test and refinement were utilized. The data collection and analysis techniques performed in this research was guided by Research Methods for Students, Academics and Professionals by Williamson & Bow (2002). Interviews were conducted with five different stakeholders to find specifications of requirements and concretize subjectivism of what defines quality and ergonomics. Implementation: Currently, below-elbow amputees order sockets from orthopedic clinics. The socket was identified as a product of Ottobock. Investigations were made to find optimal solutions to the specification of requirements. Results: The development of a socket concept was designed for additive manufacturing using a multi-jet fusion printer. Analysis: This concept had significant improvements to parameters: higher grade of customizability, 30 % reduced weight, 48 % cost reduction, a new production workflow with 93,5 % automation, and a 69 % reduction in manual work hours. Conclusions: The data of the research strongly indicate existing potentials in enhancing socket design techniques and outputs by implementation of additive manufacturing processes. This can prove to be beneficial for achieving more competitive prosthetics and associated services.