METHOD FOR PRODUCING A PROSTHESIS SHAFT, AND A PROSTHESIS SHAFT

Abstract

A method for producing a prosthesis socket in which a 3D-dataset is produced of an outer contour of a stump on which a prosthesis socket is to be mounted, and a base socket is produced from a first material in a 3D printing method using said 3D dataset, wherein an inner contour of the base socket corresponds to the outer contour of the stump, and at least one stabilising element consisting of a second material is laminated onto the base socket.

Claims

1. A method for producing a prosthesis socket, comprising: creating a 3D data record of an outer contour of a stump, to which a prosthesis socket should be applied; producing a base socket from a first substance in a 3D printing method using the 3D data record; applying at least one stabilization element that is made of a second substance to the base socket.

2. The method as claimed in claim 1, wherein the 3D data record is created by a contactless measurement method or by a tactile measurement of the stump.

3. The method as claimed in claim 1, wherein the 3D data record is complemented by at least one of entering and capturing additional stump data.

4. The method as claimed in claim 1, wherein the 3D printing method is effectuated with at least one of polymers and synthetic resins using polyjet modeling or fused deposition modeling.

5. The method as claimed in claim 1, further comprising producing a receptacle for at least one of a connection member and undercuts or projections for fixing the stabilization element on the base socket during the 3D printing method.

6. The method as claimed in claim 1, wherein the base socket is printed with an inhomogeneous wall thickness over at least one of a circumference of the base socket and a longitudinal extent of the base socket.

7. The method as claimed in claim 6, wherein, in the 3D data record, the outer contour automatically has the inhomogeneous wall thickness applied thereto.

8. The method as claimed in claim 1, wherein the at least one stabilization element is embodied as a frame, a frame part or a layer that surrounds the base socket, and arranged at the base socket.

9. The method as claimed in claim 1, wherein the at least one stabilization element includes pre-pregs that are applied to the base socket and cured under conditions of pressure and temperature.

10. The method as claimed in claim 1, wherein an anchor or a connection plate is worked into the base socket.

11. The method as claimed in claim 1, wherein an inner contour of the base socket corresponds to the outer contour of the stump or the inner contour is increased in size by a thickness of an interface between the inner contour and outer contour.

12. A prosthesis socket for receiving a stump of an extremity, the prosthesis socket comprising: a base socket with an inner contour which corresponds to an outer contour of the stump or which is increased in size by an allowance, the base socket comprising: a first substance which is processable in a 3D printing method; at least one stabilization element applied to the base socket, the stabilization element being made of a second substance which has a higher structural strength than the first substance.

13. The prosthesis socket as claimed in claim 12, wherein the stabilization element is embodied as a frame, a frame part or a layer that surrounds the base socket.

14. The prosthesis socket as claimed in claim 12, wherein the base socket has a worked-in anchor or a worked-in connection plate.

15. The prosthesis socket as claimed in claim 12, wherein the base socket has a closed cross section.

16. A method for producing a prosthesis socket, comprising: generating an at least partly circumferential panoramic image of an outer contour of a stump; creating a 3D data record of the stump based at least in part on the image; producing a base socket from a first substance in a 3D printing method using the 3D data record; applying at least one stabilization element to the base socket, the at least one stabilization element comprising a second substance.

17. The method as claimed in claim 16, wherein the 3D data record is based at least in part on a contactless measurement method or by a tactile measurement of the stump.

18. The method as claimed in claim 16, wherein the 3D data record is complemented by at least one of entering and capturing additional stump data.

19. The method as claimed in claim 16, wherein the 3D printing method is carried out using at least one of polymers and synthetic resins using polyjet modeling or fused deposition modeling.

20. The method as claimed in claim 16, further comprising producing a receptacle for at least one of a connection member and undercuts or projections for fixing the stabilization element on the base socket during the 3D printing method.

Description

[0025] An exemplary embodiment of the invention will be explained in more detail below on the basis of the figures. In the figures:

[0026] FIG. 1 shows a schematic production process for a prosthesis socket; and

[0027] FIG. 2 shows a prosthesis socket with an assembled prosthetic knee joint.

[0028] According to the production method for a prosthesis socket that is illustrated in an exemplary manner in FIG. 1, photographs of the outer contour 16 of a stump 10 are initially recorded with the aid of a digital camera 34. Here, it is possible to take two photographs or a plurality of photographs from different directions or, as described above, an at least partly circumferential panoramic image. A 3D data record 20 of the outer contour 16 of the stump 10 is produced from the photographs with the aid of a computer and evaluation software situated thereon. The 3D data record 20, which up until this point only represents the inner contour 18 of the subsequent base socket 14 and of the finished prosthesis socket 12 is subsequently complemented by further data. It was found that, with the aid of appropriate software, e.g. electronic test shaft software, TF or TT design software or CANFIT software by Vorum Research Corporation, a desired socket form and socket design can be produced on the basis of the 3D data record 20 and further desired modifications are quickly implementable. The modified 3D data record 20 is then transmitted to a 3D printer 30. In the 3D printer 30, which operates according to the fused deposition modeling principle in the illustrated embodiment, a polymer 22 or synthetic resin 22 is applied layer-by-layer and fused layer-by-layer to form a base socket 14. In the next method step, the stabilization element 32, which is available in the illustrated embodiment in the form of pre-preg strips or mats, is laminated onto the base socket 14. In the illustrated embodiment, the stabilization element 32 is embodied as a layer 28 that surrounds the base socket 14. Furthermore, a schematically illustrated anchor 24 or a connection plate 26 is laminated into the base socket 14. Subsequently, the assembled base socket 14 is exposed to a pressure and a temperature, which are higher than the ambient pressure and the ambient temperature, respectively, in a chamber that is not illustrated here such that the reaction resin of the pre-pregs cures. After the reaction resin has cured, the prosthesis socket 12 has been completed and it can be supplied to the prosthesis wearer.

[0029] FIG. 2 shows the completed prosthesis socket 12 in the assembled state. The base socket 14 has been created on the basis of the 3D data record by means of the 3D printer 30. Here, the inner contour of the base socket 14, which is not illustrated, is matched to the outer contour of the stump, i.e. it exactly corresponds to the outer contour or it was smoothed or provided with an allowance such that an interface or a liner can be arranged between the stump and the inner side of the base socket 14. The outer side of the base socket 14 may have a surface with a substantially smooth wall; in this respect, different wall thicknesses are present in the base socket 14, both over the circumference and over the length of the prosthesis socket 12. Projections 13 and undercuts 15, which serve to position and anchor stabilization elements 32, have been worked into the outer side of the base socket 14. A circumferential first stabilization element 32, for example in the form of a correspondingly formed pre-preg or a plurality of pre-pregs, which are arranged on the semi-stable base socket 14, pre-fixed and then cured under the application of pressure and heat, is arranged and fastened at the upper edge of the base socket 14 in FIG. 2.

[0030] A second stabilization element 32, the lower edge of which is seated on the projections 13 and the one side edge of which engages in an undercut 15, is arranged below the first stabilization element 32 which is arranged at the upper edge of the prosthesis socket 12 in a closed circumferential manner. The second stabilization element 32 has a clasp-like contour; i.e. the second stabilization element 32 only partly encompasses the circumference of the base socket 14. Although this brings about an increased stability of the base socket 14 in the region of the second stabilization element 32, it is possible, however, to provide a certain amount of elasticity on account of the open circumferential cross section, even if the material of the stabilization elements 32 has a substantially higher strength against a deformation than the material of the base socket.

[0031] Furthermore, FIG. 2 illustrates that the connection plate 26 and the anchor 24 are inserted and fastened or laminated into the base socket 14. In the region of the connection plate 26 and of the anchor 24, provision is made for a material thickening in the base socket 14 at the outer side thereof in order to have improved stability and sufficient space for receiving the components. The material thickening may also be effectuated by way of the stabilization element and/or the coating on the outer side of the base socket 14. In addition to the embedding into the material of the base socket and/or of the stabilization element, the connection plate 26 and the anchor 24 may also be fastened in a conventional mechanical manner, for example by screwing and/or adhesive bonding. Appropriately designed receptacle regions, alignment devices and/or stops may be embodied in the region of the fastening point of the connection plate 26 and of the anchor 24 in order to simplify the positioning of the components. A connection adapter 11 for compensating length is provided at the connection plate 26, said connection adapter in turn being coupled to the prosthetic knee joint 9, which is only indicated, such that the prosthesis socket 12 for receiving a thigh stump is connected to a below-knee part 3 in a pivotable manner.

[0032] The base socket 14 may additionally be provided with a coating, which is not illustrated here and which covers the entire outer side of the base socket 14. The coating may be applied in an immersion method or any other application method. Alternatively, the coating may also be applied only to a part of the outer side of the base socket 14; likewise, the coating may be applied, over the whole area thereof or only in part, to the inner side of the base socket 14. By way of the coating, it is possible to adjust the functionality and the surface feel and the surface design of the base socket 14; in particular, it can be adapted to the respective use. The coating and/or the stabilization elements may also be post-treated after the application to the base socket; for example, they may be subjected to heat treatment or they may be irradiated in order to obtain the desired strength properties. Thus, a skin-friendly coating may be applied to the inner side while a dirt-repellent or stabilizing coating may be applied to the outer side of the base socket 14.

LIST OF REFERENCE SIGNS

[0033] 8 Below-knee part

[0034] 9 Prosthetic knee joint

[0035] 10 Stump

[0036] 11 Adapter

[0037] 12 Prosthesis socket

[0038] 13 Projection

[0039] 14 Base socket

[0040] 15 Undercut

[0041] 16 Outer contour

[0042] 18 Inner contour

[0043] 20 3D data record

[0044] 22 Polymer/synthetic resin

[0045] 24 Anchor

[0046] 26 Connection plate

[0047] 28 Layer

[0048] 30 3D printer

[0049] 32 Stabilization element

[0050] 34 Digital camera