Design and Initial Evaluation of a Low-Cost Microprocessor-Controlled Ankle Prosthesis

Lower-limb amputation remains a significant clinical and socio-economic challenge, while the high cost of microprocessor-controlled prostheses (MPKs) limits their widespread accessibility. This paper presents the design and preliminary laboratory-scale evaluation of a low-cost microprocessor-controlled ankle prosthesis intended as a feasibility-oriented alternative platform for future active prosthetic system development. Building upon the previously developed V1 mechanical architecture, an updated CAD model was created in the SolidWorks 2024 environment, and the kinematic configuration was refined using a ball-screw transmission (SFU1204-300) driven by a NEMA 17 stepper motor. The electronic control system integrates an ESP32 microcontroller, an MPU9250 inertial measurement unit (IMU), a limit switch for initial-position detection, and a WiFi-based REST API interface for communication and control. Laboratory no-load experiments demonstrated controlled positional behavior, repeatable angular response, and successful operation of the homing procedure within a motion range of 0–4200 motor steps. The prototype actively generated dorsiflexion–plantar flexion motion in the sagittal plane, while a passive inversion–eversion mechanism was incorporated and intended to improve structural adaptability. IMU-based measurements enabled preliminary monitoring of angular displacement and positional behavior during the experiments. The presented prototype represents an initial engineering feasibility study of a low-cost active ankle actuation architecture and provides a foundation for future investigations involving load-bearing experiments, biomechanical gait analysis, and closed-loop control implementation.