3D-Printed Prosthetic Sockets Enhancing Comfort Through Stretchable Sensor Integration

Prosthetic socket design plays a critical role in the comfort, functionality, and long-term health of amputees. Traditional socket fabrication often relies on subjective fitting methods, which can lead to discomfort, pressure sores, and inadequate weight distribution. In this presentation, we demonstrate the optimal design of a stretchable horseshoe pattern, along with the insertion of sensors into the stretchable mat. Finite element analysis is performed to assess von Mises stress and deformation within the horseshoe structure and to measure the sensors’ 3D locations after stretching to the 3D form of the socket. The mat is wrapped around a positive mold of the residual limb, and liquid silicone is used to create the liner with embedded pressure sensors. The monitored pressure map data is used to create a pressure field in N-Topology software, enabling lattice design optimization of the prosthetic socket, which enhances load distribution and reduces high-stress areas that could lead to discomfort or injury. Our results demonstrate that this approach can effectively measure the 3D pressure distribution on the residual limb during the amputee's daily activities. This innovative approach holds significant potential to enhance prosthetic socket design by providing a patient-specific, data-driven solution aimed at improving the quality of life for amputees.


[1] H. Moeinnia, D.J. Agron, C. Ganzert, L. Schubert, W.S. Kim, “Wireless pressure monitoring system utilizing a 3d-printed origami pressure sensor array”, npj Flexible Electron, 8 (1) (2024), p. 21.
[2] Hadi Moeinnia, Carl Ganzert, Loren Schubert, Woo Soo Kim, “3D Pressure Mapping for Field-Driven Lattice Optimization in Prosthetic Socket Design”, to be submitted.