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.

A mechanical interface connecting a biological body segment, such as a limb, portion of a limb or other body segment, to a wearable device such as a prosthetic, orthotic or exoskeletal device, is fabricated by quantitatively mapping a characterized representation of the body segment to form a digital representation of the mechanical interface shape and mechanical interface impedance. The mechanical interface includes a continuous socket defining a contoured inside surface and a contoured outside surface, and includes a material having an intrinsic impedance that varies through the material, so that the intrinsic impedance varies along the contoured inside surface.

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 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.

Orthotic and prosthetic devices having integrated features such as cushioning features are described, as well as methods for computer aided designing and making of these devices. The orthotic or prosthetic devices comprise a cushioning layer superimposed onto an orthotic or prosthetic shell, the cushioning layer comprising an array (35) of discrete solid and resilient cushioning elements (31). In one preferred embodiment, said cushioning structure is a beam, defined around a centerline of any arbitrary shape. In another preferred embodiment, said cushioning structure has the shape of a spiral.

A mechanical interface connecting a biological body segment, such as a limb, portion of a limb or other body segment, to a wearable device such as a prosthetic, orthotic or exoskeletal device, is fabricated by quantitatively mapping a characterized representation of the body segment to form a digital representation of the mechanical interface shape and mechanical interface impedance. The mechanical interface includes a continuous socket defining a contoured inside surface and a contoured outside surface, and includes a material having an intrinsic impedance that varies through the material, so that the intrinsic impedance varies along the contoured inside surface.

A prosthetic appendage for attachment to an outer extremity of an amputated limb that is composed of modular elements fabricated by three-dimensional printing. In one embodiment the prosthetic appendage is a leg. The prosthetic leg includes a foot portion and a plurality of modular and three-dimensionally printed limb elements. One of the plurality of limb elements is pivotally coupled to the foot portion and another of the limb elements is configured at one end to receive the outer extremity of the amputated leg. In another embodiment of the present invention the prosthetic appendage is a hand. The prosthetic hand includes a wrist element with one end configured to receive the outer extremity of an amputated hand, a base portion attached to the wrist element and a plurality of modular and three-dimensionally printed finger elements selectively coupled to adjacent finger elements or the base to form prosthetic fingers.

The invention is a method of designing and manufacturing a 3D printed prosthetic socket or a standard prosthetic socket with a 3D printed distal end, comprising a step of obtaining physical data about a patient with a residual limb and a step of creating a structural design of the 3D printed prosthetic socket or standard prosthetic socket with the 3D printed distal end. The step of creating the structural design of the 3D printed prosthetic socket (3) or standard prosthetic socket with the 3D printed distal end comprises a step of determining the bulk density of the structure of the prosthetic socket between a shaped area for positioning a linking part of the liner and a distal planar area for mounting a linking adapter of the socket directly proportional to at least one of the data from a set including at least weight, patient's degree of activity, length of the residual limb, length of the prosthesis, size of the prosthetic foot, and angle between the axis of the limb and the axis of the prosthesis.

A compression stabilized prosthetic device for a patient having an amputated limb includes a first socket portion for contacting a patient's limb, and a second portion for the attachment of a prosthetic component. The first socket portion has compression portions configured for compressing portions of the patient's limb, and relief portions for receiving other portions of the patient's limb which bulge upon the compression applied by the compression portions. The relief portions may be formed as openings or as enlarged radius portions of the first socket portion.

A method and associated system for designing a biomechanical interface of a device contacting a biological body segment of a subject includes forming a quantitative model of the biological body segment from subject specific data, conducting a biophysical analysis, such as a finite element analysis, to thereby establish a relationship, such as a functional relationship, between the quantitative model and at least one feature of the biomechanical interface contacting the biological body segment, and applying the relationship to the at least one feature of the biomechanical interface contacting the biological body segment to thereby obtain an interface design for the mechanical interface of the device. The subject-specific data can include geometry of the biological body segment and the at least one feature can be associated with physiological benefit of the biological body segment.