Development of a Specialized Methodology for Custom Upper Limb Prosthesis Design in Cyclists

The growing number of upper limb amputations has highlighted the need for advanced prosthetic solutions, especially in specialized activities such as cycling. Current options for cyclists with transhumeral amputations often do not meet the necessary biomechanical and ergonomic requirements. This study proposes an innovative methodology for the personalized design of upper limb prostheses, based on an iterative process that includes 3D scanning and constant feedback from the athlete. Through a case study of a high-performance cyclist, a personalized coupling system was developed that was evaluated under training and competition conditions. In addition, stress and displacement analyses were performed to verify the structural integrity and the ability of the coupling to withstand the loads associated with cycling. The results confirmed that the design not only offers an optimal fit, but also stability and durability in real conditions. This methodology provides a promising, low-cost approach to the creation of sports prostheses that improve the performance and quality of life of cyclists with amputations.