Evolving 3D-Printing Strategies for Structural and Cosmetic Components in Upper Limb Prosthesis
Abstract
:1. Introduction
1.1. Prosthesis Classifications
1.2. Reported Limitations
1.3. Manufacturing Techniques
1.4. Aesthetic Design Considerations
2. Background
2.1. Device Development
2.2. Clinical Investigation
2.3. Aesthetic Design
3. Methods for Implementing Additive Manufacturing
3.1. Direct Part Manufacturing
3.2. Thermoforming via Additive Manufacturing Positive Die
3.3. Overmolding via Additive Manufacturing Moulds
3.4. Injection Molding Prototyping via Additive Manufacturing
3.5. Accessories and Additional Components
4. Results
4.1. Direct Part Manufacturing Outcomes for Implementing Aesthetic Design
4.2. Thermoforming Outcomes for Reduced Manufacturing Time, and Increased Durability
4.3. Overmolding Outcomes for Improved Grip
4.4. Manufacturing Accessories
4.5. Overall Weight Reduction from All Methods
5. Conclusions and Recommendations
- Prostheses are a regulated device in many countries, and clinical research often requires medical institution involvement. Patient feedback is critical to continuing the improvement of the device. Novel manufacturing methods may result in different regulatory considerations, and researchers should work closely with their institution’s compliance teams.
- The customization opportunities when using an additive manufacturing approach enable extensive aesthetic expression. Incorporating the device’s user in the aesthetic choices, referred to as a variation of participatory visual design labeled ’cooperative expression’ [19], may provide increased affinity to the device.
- Additive manufacturing is an effective tool for prototyping, and in certain use cases, but components must be mechanically designed to use traditional fasteners and to integrate into multi-part assemblies. These fasteners may include binding posts, screws, anchors, and hinges. The integration points between additive parts and traditionally manufactured components may lead to stress concentrations, and optimization for printing orientation, parameters, and applied loading conditions must be taken into account with additional caution.
- Parts manufactured by additive manufacturing may be susceptible to cyclical loading failure or part degradation over time [48], making points of integration, for example, for mechanical joints, of high priority for additional robustness.
- Additive manufacturing for the creation of positive molding, to be used with thermoforming, can allow for increased manufacturing production rates and increased part robustness. FDM-produced positive molds for thermoforming applications may be limited to 50 production pulls before cosmetic detail could be lost. The improvement in surface finish and flexibility provides excellent properties for final cosmetic parts that require aesthetic treatments.
- Cosmetic components for prosthesis are a segment of prosthesis limb manufacturing that is primed for involvement from additive manufacturing. The resulting devices may hold promise to reduce overall cost and device weight, while also being capable of producing complex visual features that would not be cost effectively manufacturable in low production volumes through other methods.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
Abbreviations
AM | Additive Manufacturing |
ABS | Acrylonitrile Butadiene Styrene |
CAD | Computer-aided Design |
EMG | Electromyography |
LSR | Liquid Silicone Rubber |
PLA | Polylactic Acid |
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Assembly | Composition & Manufacturing Method | Weight (g) | Reduction |
---|---|---|---|
Cosmesis | FDM 3D printed ABS shell, magnets, with paint | 119 | |
Thermoformed ABS shell, magnets, with paint | 80 | 33% | |
Battery Core | FDM 3D printed ABS, battery and circuitry, with paint | 177 | |
Injection moulded ABS, battery and circuitry, with paint | 169 | 5% | |
Hand | FDM 3D printed ABS, DC motors, metalic gears and supports, circuitry, with paint | 200 |
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Manero, A.; Sparkman, J.; Dombrowski, M.; Smith, P.; Senthil, P.; Smith, S.; Rivera, V.; Chi, A. Evolving 3D-Printing Strategies for Structural and Cosmetic Components in Upper Limb Prosthesis. Prosthesis 2023, 5, 167-181. https://doi.org/10.3390/prosthesis5010013
Manero A, Sparkman J, Dombrowski M, Smith P, Senthil P, Smith S, Rivera V, Chi A. Evolving 3D-Printing Strategies for Structural and Cosmetic Components in Upper Limb Prosthesis. Prosthesis. 2023; 5(1):167-181. https://doi.org/10.3390/prosthesis5010013
Chicago/Turabian StyleManero, Albert, John Sparkman, Matt Dombrowski, Peter Smith, Pavan Senthil, Spencer Smith, Viviana Rivera, and Albert Chi. 2023. "Evolving 3D-Printing Strategies for Structural and Cosmetic Components in Upper Limb Prosthesis" Prosthesis 5, no. 1: 167-181. https://doi.org/10.3390/prosthesis5010013