Study and Analysis of the Effects of Increasing Carbon Fiber Layers on the Physical and Creep Characterization Used for Lower Limb Prosthetic Socket Laminations

Background Prosthetic sockets for lower limb amputees are subject to hazardous loading conditions—especially in high ambient temperatures that exacerbate creep behavior, leading to material deformation, increased stress, and reduced comfort and performance. Aim This study investigates whether integrating carbon fiber layers into conventional Perlon composite laminations can mitigate temperature‐induced creep deformation in prosthetic sockets. Methodology Baseline specimens consisted of six‐layer Perlon laminations (3p + 0c + 3p). Creep tests were conducted under controlled loads at three temperature levels (room temperature, 40, and 60°C) over predetermined time intervals to evaluate deformation, stress, and strain responses. Hybrid laminations were prepared by inserting one (3p + 1c + 3p), two (3p + 2c + 3p), and three (3p + 3c + 3p) carbon fiber layers centrally within the Perlon layers; identical creep tests were performed on each configuration. Results Compared to room temperature, the baseline (3p + 0c + 3p) specimens exhibited creep deflection increases of 208.8% at 40°C and 272.2% at 60°C. Incorporating one carbon fiber layer (3p + 1c + 3p) reduced this to 102.3% and 250%, respectively. For two carbon layers (3p + 2c + 3p), the increases were 8.75 % at 40°C and 212.8% at 60°C. With three carbon fiber layers (3p + 3c + 3p), creep deformation rose by only 6.2% at 40°C and 110.9% at 60°C. Similar trends were observed in creep strain across the configurations. Conclusion Adding carbon fiber layers to Perlon‐based laminations significantly reduces temperature‐induced creep deformation in prosthetic sockets. The most effective configuration in this study featured three centrally embedded carbon fiber layers, which offered the greatest mitigation—particularly at moderate temperature increases. Future Directions Further studies should evaluate long‐term durability under cyclic loading and real‐world use conditions, explore optimal layer orientation and thickness, and assess biomechanical implications and manufacturability in clinical settings.