Development and Modeling of a Modular Ankle Prosthesis

This paper presents a low-cost, modular ankle–foot prosthesis that integrates an S-shaped compliant foot with a parallel spring–short-stroke actuator branch to balance energy return, impact attenuation, and rapid personalization. The design follows an FDM-oriented CAD/CAE workflow using PETG and interchangeable modules (foot, ankle unit, pylon adapter). Finite-element analyses of heel-strike, mid-stance, and toe-off load cases, supported by bench checks, show strain localization in intended flexural regions, a minimum safety factor of 15 for the housing, and peak-stress reduction after geometric refinements (increased transition radii and local ribs). The modular layout simplifies servicing and allows quick tuning of stiffness and damping without redesigning the load-bearing structure. The results indicate an engineeringly realistic path toward accessible prosthetics and provide a basis for subsequent upgrades toward semi-active control and sensor-assisted damping.