3D-printed prosthetic leg socket for sustainable production and consumption

Purpose Three-dimensional (3D) printing technology has emerged as a versatile tool in wearable applications, enabling the creation of personalized components that are cost-efficient and mechanically robust. This study aims to explore the optimization of prosthetic leg sockets using 3D printing to cater to individual user requirements. Design/methodology/approach Three structures − a cube, truncated cube and octet truss − were fabricated and subjected to compression tests to measure their compressive strengths. Finite element analysis was used to identify the most suitable structure for prosthetic leg sockets. Additionally, two repair methods for damaged structures were experimentally evaluated: attaching a 3D-printed reinforcement structure and direct 3D printing of the damaged section. Findings The octet truss demonstrated the lowest density, while the cube exhibited the highest fracture load. When reinforcement structures were attached, the bonding angle was found to significantly affect mechanical strength. Furthermore, structures repaired through direct 3D printing showed mechanical properties comparable to those of the original models. Originality/value This study highlights the utility of 3D printing for damage repair and the potential of lightweight, 3D-printed structures in enhancing mechanical strength. These findings can be extended to other materials, such as ceramics and metals, for wearable applications, suggesting that structural optimization could improve the compressive strengths of materials used in wearable devices.