Case Study 04

Prosthetic Socket

A scan-to-design engineering concept combining reverse engineering, a 1000 N static study, topology-informed redesign, and additive-manufacturing preparation.

Prosthetic Socket

Optimization has to become buildable geometry.

The page separates structural outputs and manufacturing orientations so each stage can be inspected individually.

Concept only — engineering study, not a clinically validated medical device.

01
Reference geometry

Create the socket concept from a digital reference.

The workflow begins with a reference limb model prepared from mesh data and proceeds into reverse-engineered socket geometry.

Mesh referenceReverse engineering
Initial prosthetic socket geometry
1000 N static study — separated outputs

Three results.
Three full-scale figures.

The original combined simulation figure has been split into independent displacement, stress, and strain images.

Displacement

Maximum displacement reported in the source figure: 0.02 mm.

Prosthetic socket displacement result

von Mises stress

Standalone stress output from the static-study source figure.

Prosthetic socket stress result

Strain

Standalone strain output from the static-study source figure.

Prosthetic socket strain result
02
Redesign

Translate the structural study into smoother geometry.

The topology-informed concept was converted into a smoother structure with filleted cutouts, ventilation, and reduced support demand.

Filleted cutoutsVentilationTopology-informed
Redesigned prosthetic socket
03
Build orientation

Compare a more self-supporting orientation.

Manufacturing preparation considered build orientation, material use, time, and support demand.

Build orientationMaterial use
Prosthetic socket build orientation A
04
Support comparison

Review an alternate orientation with support structures.

The second orientation makes the support requirement visually explicit, helping compare additive-manufacturing tradeoffs.

SupportsAM preparation
Prosthetic socket build orientation B
Modeled outcome
57%

Mass reduction: 740 g → 321 g

The portfolio reports a reduction in modeled mass after the iterative redesign.

Concept boundary

Concept only — engineering study, not a clinically validated medical device.

0.02 mmMaximum displacement reported
1d 15h 19mPrinting estimate shown in source
57%Modeled mass reduction