
Data-Driven Radially Outward Graded Gyroid Lattice-Based Design and Fabrication of Transfemoral Prosthetic Socket via Material Extrusion Additive Manufacturing
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Friction between residual limb tissues and prosthetic socket (PS) walls often causes sweat accumulation, leading to wounds and ulcers that limit daily usage [1]. To overcome this, a lightweight, perforated transfemoral prosthetic socket (TPS) was developed to promote airflow and enhance user comfort. The design was derived from a 3D scan of a transfemoral amputee’s limb converted into an implicit model. Finite element analysis (FEA) in nTop software generated a stress field that guided the creation of a radially outward graded gyroid lattice structure, optimizing strength. Further, the TPS was fabricated using polyethylene terephthalate glycol (PETG) via the material extrusion (MEX) additive manufacturing process, and a compression test was conducted. The result elucidates that a deformation of 5 mm at a load of 400 N remains within the safety limit. This study presents a data-driven customizable approach for PS design that integrates structural stability with improved comfort and breathability.