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Design and manufacturing process optimization for prosthesis of the lower limb

Abstract : The prosthetic socket, an essential interface element between the patient's stump and prosthetic device, is most often the place where the degree of prosthetic success is defined. It is the most critical part of the prosthesis, customized to fit with the unique residual limb of the amputee. Without a proper socket shape and fit, the prosthesis becomes uncomfortable, or even unusable, and causes pain and skin issues. The state-of-the-art prosthetic production is still missing universal numerical standards to design a socket. The current practice is expensive and relies on the manual refinements of the orthopedic technician, and the fit quality strictly correlates with his skills as well as the subjective feedback of the patient. The thesis aims to conduct a deep analysis of an optimal design of the prosthetic socket by studying and developing an alternative computer-aided design process. This process is fully based on the virtual model of the patient’s residual limb and relies on the calculation of the socket-stump interaction. A fast calculation is favorable in this case, that’s why we propose to use the Mass-Spring System (MSS) instead of the widely used FE method to model the soft tissues of the residual limb. A new configuration of the MSS model is proposed to respect the non-compressibility property of the soft tissues by adding non-linear “Corrective Springs”. The numeric model is to be generated from the scanned model of the stump. For this purpose, we propose a fusion scheme of four RGB-Depth sensors for a rapid and low-cost scan with error reduction techniques. Finally, the virtual residual limb is used in the socket designing phase. A parametric design method is proposed and investigated. The design problem is transformed into a constraint-satisfaction-problem whose constraints are derived from the inverse calculation of the stump-socket interaction. The inverse approach has been chosen to eliminate the need for expensive contact formulation. This fact leads to rapid calculations, and consequently, allows to provide real-time numerical feedback during the designing process. The validation was done by comparing the results of our system with the output of FE simulations. The system has been implemented with a user-friendly graphical interface and virtually tested and numerically validated. This system reduces the limitations of the current practices. However, a lot of works is still ahead to refine and develop the system and validate it with clinical experiments.
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Submitted on : Sunday, August 1, 2021 - 10:21:10 PM
Last modification on : Monday, September 13, 2021 - 4:40:59 PM


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  • HAL Id : tel-03311669, version 1



Abbass Ballit. Design and manufacturing process optimization for prosthesis of the lower limb. Biomechanics []. Université de Technologie de Compiègne, 2020. English. ⟨NNT : 2020COMP2589⟩. ⟨tel-03311669⟩



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