A flexible prosthetic inner socket that resides inside of a rigid prosthetic socket that is fabricated by forming a sized, injection molded, flexible inner pre-socket. The flexible inner pre-socket includes a body formed with an opening and an enclosed end. The Pre-socket can be heated and stretched over a prosthetic residual limb model and then a prosthetic rigid socket can be formed over it. It can also be heated and vacuum-formed inside of an existing hard prosthetic socket in order to provide global volume reduction intended to make the rigid prosthetic socket fit tighter onto the residual limb. The opening of the flexible inner socket may be trimmed after the formation to fit contours of an opening of the rigid prosthetic socket.

An air hammock for a prosthetic with dynamic conformity to better match to the underlying limb shape in real-time through a combination of structural support members with modularly adjustable compliant members thereby creating an air hammock for a prosthetic by suspending the limb within the socket without pressure on the bottom of the residual limb.

Apparatus is provided to cushion between a prosthetic socket and an amputee's residual limb. A plurality of putty-filled packets are assembled into a liner that, when assembled, provides a generally smooth contact surface toward the residual limb. At least one of the packets has a fluid bladder positioned between the putty material and the socket, and the fluid volume in the bladder can be adjusted to affect the fit of the assembly on the residual limb. Methods of fabrication, fitting, and use of such prosthetic devices are disclosed.

In one aspect, novel robust electroactive polymers (EAPs) is described, which contract and expand at low voltages to provide for a shape-morphing system, e.g., a prosthetic liner, and potentially entire prosthetic socket, to contract and expand in strategic areas as needed to maintain a comfortable and good fit throughout the day. In some embodiments, as the residual limb changes, these novel robust EAPs can change dynamically as needed to maintain a comfortable, snug fit of the prosthetic liner or socket with the hard shell of the prosthetic socket device. In some embodiments, the EAPs used in prosthetic liners or sockets can also be used to detect pressure as the device is being used, and automatically adjust to maintain fit through a control unit, so that the patient does not even have to stop and adjust his or her device as he or she goes about an active day.

A system for joining a limb liner to a prosthesis. The prosthesis has a socket that is joined to the remainder of the prosthesis using a hub assembly. The hub assembly includes a first hub and a second hub. The first hub is disposed within the interior of the socket. The second hub is disposed outside the interior of the socket. An air conduit extends through the hub assembly that enables air to be drawn into the socket and/or vented from the socket. An inflatable interface is disposed within the socket. The inflatable interface receives air through the air conduit in the hub assembly. The inflatable interface is capable of filling any gaps that may exist between a limb liner being worn by an amputee and the socket.

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 dynamic support system includes a control system for controlling inflation and deflation of at least one actuator having an inlet connectable to the a control unit of the dynamic support system. The control unit may be in communication with a sensor and may control inflation and deflation of the at least one actuator in response to information provided by the sensor.

A dynamic support apparatus having a frame, a dynamic interface, a temperature control mechanism, and a control system. The dynamic interface is capable of changing its geometry and is disposed on the top surface of the frame. The control system is operably connected to the dynamic interface and controls the changing geometry of the dynamic interface. There is also a temperature control mechanism disposed on the top surface of the frame for maintaining a comfortable temperature and moisture environment between the apparatus and the user's body.

A control unit system. The system includes a control unit which includes a control unit charging interface, at least one magnet located proximate to the control unit charging interface, at least one actuator, a detachable manifold including at least one magnet, fluidly coupled to the at least one actuator, a pump connected to the at least one actuator for causing actuation thereof, and a control system for controlling the pump, wherein the control system controls the pump to actuate the at least one actuator at least in response to a signal received by the control system. The system also includes a recharging device configured to receive the control unit, the recharging device including a reed switch, wherein when the magnet in the control unit is located proximate to the reed switch, the switch is activated.

Systems and methods are described herein for a prosthetic device that includes a premade outer shell socket with an inner surface contour. A prosthetic insert socket is manufactured via a manufacturing process, such as three-dimensional printing, to have an outer contour that corresponds to the inner surface contour of the premade outer shell socket. The prosthetic insert socket is manufactured to have an inner contour that corresponds to a residual limb surface contour of a patient.