Computational Design and Additive Manufacturing of 3D-Printed Prosthetics for Enhanced Mobility and Performance

This paper discusses the potential application of computational design and additive manufacturing in veterinary prosthetics, demonstrated with the example of a feline limb. A finite element analysis (FEA)-based design optimization framework was used to develop eight prosthetic leg geometries in CAD and analyze them in ANSYS (2024R) under a static loading condition, to evaluate their performance under the loading condition. Structural variations were in the form of grooves, holes and shell reinforcements, which were investigated to see how they affect stiffness, stress distribution and viability of the 3D-printed prosthetics. Design variations were introduced through the inclusion or exclusion of structural attributes such as grooves, holes, and shell reinforcements. The simulations evaluated total deformation, von Mises stress, and equivalent elastic strain to determine the mechanical efficiency of each configuration. Results showed that designs incorporating shells and holes provided the best overall performance, as groove-free designs minimized stress concentrations and achieved the highest stiffness. Notably, the configuration featuring a hole and shell without grooves achieved the lowest mean deformation (14.09 µm) and stress values, making it the most structurally viable and suitable for real-life application. This study highlights the potential of 3D printing to produce cost-effective, patient-specific prosthetics and underscores the importance of structural optimization for improving biomechanical compatibility and mobility. The next stage of this work will involve fabricating the optimized design using 3D printing, followed by mechanical testing to validate the simulation results and assess real-world performance. Future work will also incorporate topology optimization to further reduce weight while maintaining structural integrity.