Optimizing Mechanical Design for an Additively Manufactured Prosthetic Leg

Abstract

The study discussed in this paper focuses on additive manufacturing (AM) of intricate geometrically structured components of a prosthetic leg. The objective is to optimize the original design to reduce the need for support structures while maximizing stiffness and reducing weight. Making a prosthetic leg lighter can improve the mobility of a person and reduce the energy required to climb stairs, enhancing their quality of life and independence. Traditional manufacturing methods, such as injection molding and computerized numerical control (CNC) machining, have limitations in terms of design flexibility. The study used Selective Laser Melting (SLM) technology with 316L-A stainless steel powder. The optimization process focused on the knee, upper leg, lower leg, hydraulic, and oil support system. The workflow procedure for additive manufacturing was discussed. Overall, the study successfully reduced the weight of the prosthetic leg by 50% from the original model.