A pre-operative planning and manufacturing method for orthopedic surgery includes obtaining pre-operative medical image data representing a joint portion of a patient. The method also includes constructing a three-dimensional digital model of the joint portion and manufacturing a patient-specific alignment guide for the joint portion from the three-dimensional digital model of the joint portion when the image data is sufficient to construct the three-dimensional digital model of the joint portion. The patient-specific alignment guide has a three-dimensional patient-specific surface pre-operatively configured to nest and closely conform to a corresponding surface of the joint portion of the patient in only one position relative to the joint portion. The method further includes determining, from the image data, a size of a non-custom implant to be implanted in the patient and assembling a surgical kit including the non-custom implant when there is insufficient image data to construct the patient-specific alignment guide therefrom.

The invention relates to a method for producing a prosthetic liner for insertion into a prosthetic socket, which comprises a receptacle having a distal end and a proximal edge for a residual limb and the prosthetic liner. Said The method comprises determining a sealing lip contour on the outer face of the prosthetic liner which corresponds to a height contour of the proximal edge of the prosthetic socket, or on the basis of available, known anatomic characteristics of the residual limb and arranging a sealing lipon the outer face of the prosthetic liner along the determined sealing lip contour.

A flexible inner socket is fabricated by forming a pre-socket. The pre-socket includes a body formed with an opening and an enclosed end. The enclosed end is opposite to the opening. The body of the pre-socket has an outer circumference that is smaller than the inner circumference of the rigid prosthetic socket. Different portions of the body may have different thicknesses. The preform socket is heated. After the heating, the flexible inner socket is formed by molding the pre-socket onto the inner surface of the rigid prosthetic socket to form the flexible inner socket. The inner circumference of the rigid prosthetic socket is reduced by a thickness of the flexible inner socket when the flexible inner socket is attached to the inner surface of the rigid prosthetic socket. An opening of the flexible inner socket may be trimmed after the formation to fit contours of an opening of the rigid prosthetic socket.

A sheath made of an elastomer material for a prosthesis liner comprises an inner wall and an outer wall defining a sheath body that extends between a proximal end suitable for placing the sheath body onto a stump and a distal end. The sheath is provided at the distal end thereof with a conformable cavity that is formed in the sheath body and is open to the outside via an opening.

An orthotic device for a patient's foot includes a shell that is configured to structurally support the patient's foot. The shell has a variable thickness along a dimension of the shell. The shell is configured to undergo flexion throughout the shell. The variable thickness of the shell targets areas of increased stress.

A support structure, a prosthesis component, and a method for producing a prosthesis component.

Disclosed herein are a method and system for producing a digital model of a customised device, comprising the steps of: importing a first digital file of a base part; importing a second digital file of a target shape; determining a warping interpolation function based on source point positions associated with the base part and target point positions associated with the target shape; and applying the warping interpolation function to the points of said base part to generate a model of said customised device.

A suspended sleeve assembly includes a suspension stand and a compression sleeve. An upper portion of the compression sleeve is attached onto the suspension stand, but a lower portion of the compression sleeve is unattached from the suspension stand. The suspended sleeve assembly can also include a support stand. The suspended sleeve assembly can be used to shape a prosthetic socket. The compression sleeve applies a circumferential pressure onto the prosthetic socket as the prosthetic socket is being inserted into the compression sleeve as a patient steps into the compression sleeve and applies at least a portion of body weight to the compression sleeve. The prosthetic socket can be heated and shaped by hand, so that it fits the residual limb of the patient. The suspended sleeve assembly can also be used to shape other prosthetic components, such as a negative plaster cast.

A system and a method for creating prosthetics using a prosthetic machine are disclosed. The method includes creating a three dimensional (3D) shape of a prosthetic using a software. Successively, the 3D shape is sent for printing based at least on an availability of a printer. The printing is achieved by taking the 3D shape and slicing into very thin horizontal slices and thereafter placing a slice upon a slice for the 3D shape. Further, granular polycarbonate material is placed in a cartridge at the top of a compression head. Further, granules are fed through a four stage heating and compression process. Further, a heated plastic is pressurized and forced through an extruder to extrude in a 1 mm×4 mm ribbon. Thereafter, a printed object is formed on a base plate through motion that is controlled by a plurality of linear axes and a rotary axis.

A compliant prosthetic foot is designed and fabricated by combining a compliant mechanism optimization technique with a calculation of low leg trajectory error under a reference loading condition. The compliant mechanism optimization technique includes a set of determinants for the compliant prosthetic foot. An optimized set of determinants of the compliant prosthetic foot is formed that minimizes the lower leg trajectory error relative to a target kinematic data set. The compliant prosthetic foot is then fabricated in conformance with the optimized set of determinants.