Streamlined custom manufacturing for optimized 3D printed prostheses through 3D pressure mapping

This study introduces a novel digital workflow for prosthetic socket design that integrates 3D pressure mapping with density-graded lattice structures to improve comfort and reduce impact forces at the limb-socket interface. A wearable liner embedded with capacitive, origami-inspired pressure sensors and flexible interconnections was used to measure dynamic contact pressures on a transfemoral amputee during six static postures and four activities, including standing, side leaning, walking, and ramp descent. Peak pressures reached up to 7500 kPa, with ramp descent exhibiting the most critical load distribution. The pressure data were processed using a weighted averaging method to generate a 3D pressure map, which guided the density grading of three cellular infill types like Gyroid, Diamond, and Neovius. Finite Element Analysis demonstrated that the graded Gyroid structure absorbed up to 1600% more energy than a solid infill during standing and 1290% more during walking. These findings validate a pressure-informed, additively manufactured socket design approach that effectively mitigates localized contact pressures and has the potential to enhance user comfort and prosthetic performance.