Foundations for Future Prosthetics: Combining Rheology, 3D Printing, and Sensors

The rising global demand for prosthetic limbs, driven by approximately 185,000 amputations annually in the United States, underscores the need for innovative and cost-efficient solutions. This study explores the integration of hybrid materials, advanced 3D printing techniques, and smart sensing technologies to enhance prosthetic finger production. A Taguchi-based design of experiments (DoE) approach using an L09 orthogonal array was employed to systematically evaluate the effects of infill density, infill pattern, and print speed on the tensile behavior of FDM-printed PLA components. Findings reveal that higher infill densities (90%) and hexagonal patterns significantly enhance yield strength, ultimate tensile strength, and stiffness. Additionally, the rheological properties of polydimethylsiloxane (PDMS) were optimized at various temperatures (30–70 °C), characterizing its viscosity, shear-thinning factors, and stress behaviors for 3D bioprinting of flexible sensors. Barium titanate (BaTiO3) was incorporated into PDMS to fabricate a flexible tactile sensor, achieving reliable open-circuit voltage readings under applied forces. Structural and functional components of the finger prosthesis were fabricated using FDM, stereolithography (SLA), and extrusion-based bioprinting (EBP) and assembled into a functional prototype. This research demonstrates the feasibility of integrating hybrid materials and advanced printing methodologies to create cost-effective, high-performance prosthetic components with enhanced mechanical properties and embedded sensing capabilities.