A device for assisting taking digitisation impressions of the remaining part of an amputated limb of a patient for generating a 3D model of a femoral prosthesis socket, that includes: a base, at least two transparent tongues secured to the base and suitable for being applied against the remaining part of the amputated limb, and means for clamping said tongues on the remaining part of the amputated limb.

Systems and methods for creating custom-fit prosthetic devices, orthotic devices, and related medical devices via three-dimensional printing (3D printing) or additive manufacturing techniques are described. Through the described systems and methods, a residual limb or other body part of a patient is scanned and analyzed to determine measurements and characteristics of the residual limb. The measurements and characteristics of the residual limb are used to design a customized device for the residual limb. The customized device uses multiple different materials. For example, the customized device may use a first material for a frame and a second material for a liner, wherein the first material is more rigid than the second material. The customized device is fabricated using a three-dimensional printer that is capable of printing and bonding multiple different materials at the same time.

A prosthesis, radiation bolus, pre-surgical model, or burn mask formed using a rapid prototyping device, such as a three-dimensional printer. In some exemplary aspects, the prosthesis includes a scaffolding and a coating at least partially covering the scaffolding. Methods and systems for forming the prosthesis, radiation bolus, pre-surgical model, or burn mask are also provided.

A lower limb modular prosthetic system that may be fabricated by a 3D printer capable of printing with composite fiber filament, nylon, or metal. The production process may include a 3D printer that is capable of routing fiber in specifically programmed patterns. The components of the prosthetic system may be designed for direct patient end-use, and may be energy returning in nature.

The disclosure provides apparatus and methods of use pertaining to a prosthetic finger assembly. In one embodiment, the assembly includes a coupling tip and a distal ring coupled with the coupling tip. The assembly further includes a proximal ring coupled with the distal ring. A rocker formed in an H-shape with a first end forming a first split prong and a second end forming a second split prong may extend between the coupling tip and the proximal ring. The coupling tip, distal ring, proximal ring, and H-shaped rocker may all be hingedly connected such that movements of the residual finger within the proximal ring articulate the distal ring together with the rocker to articulate the coupling tip. Other embodiments are also disclosed.

The invention relates to a computer-implemented method for producing an orthopedic device. The method includes receiving at least one data set with patient data, processing the patient data in order to create a patient model, using the patient model to determine patient parameters, and generating a virtual representation of the orthopedic device while using the patient parameters and device parameters. The method further includes receiving at least one input from at least one user, modifying at least one of the patient parameters or device parameters on the basis of the input, and physically creating the orthopedic device.

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.

An apparatus and manufacturing method for a reinforced fill-compositing prosthetic device. A prosthetic device is manufactured according to an additive manufacturing method. The prosthetic device is manufactured with a multitude of internal channels running in one or more linear or angular paths relative to a calculated sheer force direction, which may follow the contours of the prosthetic device. Channels defining an internal structure of a socket wall are open on at least one end of the prosthetic device. One or more structural inserts comprising a strength tested tensile strength material, such as carbon fiber, are inserted into the channels and bonded into place.

An additive manufacturing method and apparatus for interchangeable local interface support geometry and materials in lower limb prosthetic sockets. An interchangeable local interface prosthetic socket is configured to enable a user of the socket to configure variable support, pressure, and comfort characteristics of lower limb prosthetic sockets by selectively replacing an interface panel and/or distal cup with an alternative interface panel and/or distal cup being configured to have different physical characteristics.

A two-part prosthetic socket which includes an inner socket component having an inner profile substantially complementary to a profile of a residual limb of a patient, and an outer socket component configured to releasably attach about an outer surface of the inner socket component is disclosed. The inner profile of the inner socket component may be determined from digital data output from a medical imaging scan of the residual limb, which provides a three-dimensional digital profile of the residual limb that includes information on the size and location of at least bone and bone spurs, muscle, scar tissue, and neuroma. The digital data may further include a designed operating range for the size and shape of the three-dimensional digital profile of the residual limb based on such information. The two-part prosthetic socket may be manufactured using additive manufacturing, wherein the inner socket may be formed of a flexible material and the outer socket may be formed of a rigid material.