Optimizing energy storage and return of prosthetic feet: A biomechanical approach using advanced optimization techniques

• A novel design framework that leverages advanced optimization techniques, including Latin Hypercube Sampling (LHS), Kriging, and Muti-Objective Genetic Algorithm (MOGA) to improve the prosthetic foot design. • The prosthetic foot's middle and lower blade thickness are critical parameters affecting force reaction and stress distribution to minimize weight while maximizing stiffness and energy return. • Finite Element Analysis (FEA) validated the ability of the design to withstand daily stress according to ISO 1328 standards for prosthetic testing. Energy Storage and Return (ESR) prosthetic feet are vital in restoring natural gait biomechanics for individuals with lower-limb amputations. This study introduces a novel design framework that combines Latin Hypercube Sampling (LHS), Kriging, and a Multi-Objective Genetic Algorithm (MOGA) to optimize weight, stiffness, and energy return. Aluminum alloy was selected for its balance of strength, affordability, and manufacturability. Finite Element Analysis (FEA) validated the structural performance under ISO 10328 loading conditions. The results demonstrate that, despite aluminum having lower impact resistance than carbon fiber, its energy return during walking is comparable, differing by 19% while maintaining an appropriate Range of Motion. These findings highlight the potential of aluminum as a cost-effective alternative without compromising key biomechanical performance. The proposed framework enables the development of lightweight, resilient prosthetic feet that align with user biomechanics and may reduce overall cost barriers to solutions.