A liner is arranged for use in prosthetic and orthopedic devices. The liner defines first and second end portions, and inner and outer surfaces. The liner includes an inner layer having a frictional component and forms at least part of the periphery of the inner liner surface. The inner layer defines a plurality of apertures. A porous element is in communication with the inner liner surface and is connected to the inner layer such that the apertures permit a transfer of air from the inner surface to the porous element. A base layer adjoins the porous element and extends between the first and second end portions of the liner.

A prosthetic interface includes a body portion having an open proximal end and a closed distal end including a distal cup. The body portion includes a membrane component having a flexible configuration defining an internal flow space extending along a length of the membrane component between an inner side arranged to face a skin surface of a residual limb and an outer side arranged to face away from the skin surface. At least one material coating is selectively applied to the membrane component that interacts with at least one of the membrane component and the distal cup to define at least one breathable region along the inner side that allows fluid flow between the internal flow space and the residual limb, and at least one impermeable region along the outer side that allows for vacuum suspension between the prosthetic interface and a prosthetic socket.

A thermally responsive shape memory polymer (SMP) actuator includes a body having at least one non-linear segment arranged between first and second ends, with the body comprising a plurality of dots, rods, or layers of SMP material. The SMP material my include a linear aliphatic thermoplastic polyester and at least one other polymer. The non-linear segment may have a substantially flat zig-zag shape arranged between first and second substantially straight segments. A prosthetic device may include multiple thermally responsive shape memory actuators and a movable joint arranged between structural members having anchors associated therewith. At least one first SMP actuator provides pivotal movement in a first direction, and at least one second SMP actuator provides pivotal movement in a second direction. Methods for forming SMP actuators include body formation by additive manufacturing, heating the body to a glass transition temperature range while applying tension, and cooling the body.

A hollow tubulous composite structure and method for prosthetic limbs is described.

A prosthetic lower leg uses one or more generally C-shaped spring elements between the patient's socket and a foot-plate assembly. The respective connections between (a) those one or more elements and (b) that socket and that footplate can be configured to provide a lightweight and economic prosthesis that effectively mimics the feel and performance of a normal human foot. The prosthetic spring element is generally C-shaped, and can have a substantially constant thickness along its length, lending itself to being fabricated by automated processes such as filament winding. One or more of the generally C-shaped spring elements can be incorporated into other prostheses and/or other devices.

A prosthetic foot (200) that does not require metallic connectors to attach carbon fiber leaf springs (201) and (202) is provided. The carbon fiber leaf springs (201) and (202) are attached together by three-dimensionally stitching prepreg preforms of the carbon fiber leaf springs (201) and (202) at the junction (203) of the carbon fiber leaf springs (201) and (202), and then further curing the stitch attached prepreg preforms. In another embodiment, a woven interlayer attached the two carbon fiber leaf springs (201) and (202).

Various embodiments of the present invention generally relate to prosthetic partial finger designs that can mimic the last two joints of the finger. Some embodiments include a proximal phalange, a distal phalange coupled to the proximal phalange, and a knuckle track (e.g., formed in an arc). The knuckle track can be moveably coupled to the proximal phalange an may include multiple teeth formed on which the proximal phalange slides along. A ratcheting mechanism can contact the multiple teeth to allow sliding in only a first direction while the ratcheting mechanism is engaged. Some embodiments include a release mechanism (e.g., a button) configured to disengage the ratcheting mechanism from the multiple teeth to allow the distal phalange to slide in a second direction. In some embodiments, the device may include a spring-back capability that automatically extends the finger after reaching full finger flexion, enabling one-handed use.

A prosthetic lower leg uses one or more generally C-shaped spring elements between the patient's socket and a footplate assembly. The respective connections between (a) those one or more elements and (b) that socket and that footplate can be configured to provide a lightweight and economic prosthesis that effectively mimics the feel and performance of a normal human foot. The prosthetic spring element is generally C-shaped, and can have a substantially constant thickness along its length, lending itself to being fabricated by automated processes such as filament winding. One or more of the generally C-shaped spring elements can be incorporated into other prostheses and/or other devices.

A system and method for method including receiving data representing coordinates of a shape of a body part, forming a model of a flexible inner liner based upon the received data, the flexible inner liner configured to be placed over the body part, receiving, as input, a thickness and an offset of the model of the flexible inner liner, assigning a default density to an internal structure of the model; and varying the default density of the model without changing an outer geometry of the model to create a modified model of the flexible inner liner.

A method for manufacturing a customized sleeve for a prosthesis, comprises the following steps: (a) providing a mold of an end of a limb of an individual who is intended to receive said prosthesis; (b) providing a preform made of an elastomer material, said preform comprising an open proximal end and a closed distal end; (c) positioning said preform on the mold; (d) positioning on said preform at least one element from: a polymer reinforcement, a layer of an elongation-preventing fabric, a distal cup and an air discharge sheath; (e) positioning a vacuum cover around the preform; (f) creating a vacuum and injecting a polymer cross-linkable at room temperature into said vacuum cover so as to form a coating having a uniform thickness over the preform and each element which is positioned on said preform.