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Capstone Project 2017-2018

Mahidol University International Demonstration School

Prosthetic Leg Design and Model

Presented To

Ms. Susana Alulod


Mr. Andrew Filipczak
Ms. Chomkate Ngamkaiwan

By

Wanwarisa Krittiyasrisumet 5961191


Pemika Phatthanakittichai 5961142
Phatsakorn Rodphol 5961175
Introduction

What are prosthetic limbs?


Prosthetic limbs are artificial devices made to substitute the limbs that are amputated. A
prosthetic is often designed to be functional or for cosmetic purposes. A functional prosthetic
allows the users to have more agility, but cosmetic prosthetic focuses more on the appearance of
it than how it functions. According to Woodford C. (2016), there are generally two types of
prosthetic limbs. One is below the knee (BK, transtibial), which is a prosthetic that is attached
below the knee part. Above the knee (AK, transfemoral) is another type of prosthetic, which the
length will be long, so it will attach to the upper part of the leg. This also includes prosthetic
knee. Our prosthetic is the transfemoral type with the socket attaching to the part above the
knees.

How does a prosthetic work?


Prosthetic consists of different parts that work in different ways. First, the
prosthetic limb has to be able to bear with the entire weight of the body. It
has to be strong, durable, but lightweight in order to make it feels like
natural leg. How well the prosthetic fits and secures to the residual limb (the
remaining part of the patient’s own limb) is controlled by the attachment
mechanism called a suspension system. It purpose is to make patient feel
comfortable and make sure that the prosthetic can be properly controlled.
Socket is one of the attachment mechanism. It is the part that connect the
prosthetic to the residual limb. The socket governs the comfort and
effectiveness of the prosthetic, depending on how it fits to the real limb and
how comfort the patient will feel when wearing the prosthetic.

The Main Part of the Prosthetics


The first part of the limb is the skeletal part, which is the internal part of the limb and also be
known as the pylon.The function of the skeletal part is to give the structural support and usually
made out of the carbon fiber. Most of the time, the pylon usually shape and color same as the
person skin tone in order to make it's become more natural. The second part of the limb is the
socket , which interface with the person’s limb stump. Function of the socket is to transforms the
force from the artificial limb to the person’s body. The socket have to be fitted perfectly with the
person limb in order to avoid the irritation of the skin. The user have to wear the prosthetics sock
to get better fit and help to avoid the irritation. The third part of the limb is the suspension
system. The function of the suspension system is to keep limb attach to the body of the user. For
example, the straps, belts, and sleeves. Each part of the prosthetics devices will have their own
unique design and category of amputation according to the need of the patients.
3D Printed Prosthetics Versus Traditional Prosthetics
As we have stated before, our goal is to create a prosthetic leg that is accessible to people of all
ages, and social statuses, specifically the working class people. From the research that we have
done, the price for a traditional prosthetic leg varies from 150,000 THB to 220,000 THB ($5000
to $7,000) for a basic prosthetic for walking on flat ground. The price could then go up from
310,000 THB to 620,000 THB ($10,000 to $20,000)for a prosthetic with a system that allows the
user more movement control, and it would even cost from 1.5 million THB to 2.2 million THB
($50,000 to $70,000) for a prosthetic that is computerized. As for our 3D printed prosthetic, the
price is between 20,000 THB to 50,000 THB ($700 to $1600)

Objectives
Our objectives in doing this project are firstly, to find an alternative way to make prosthetic legs
at an affordable price for people with lower income. We also wanted to understand the
mechanisms of the prosthetics and how they function.

Purpose of the prosthetic


Our prosthetic is designed to help comfort disable people, so that they can walk smoothly on
their own. Our prosthetic would be in an affordable price, meaning that people with less income
can afford this prosthetic for their benefits.

Characteristics/ Features
Features of our prosthetic legs should be able to support the living conditions of the user and the
surrounding environment the user lives in. We are focusing on the conditions and weathers of
Thailand. Therefore, our prosthetic legs’ features should include lightweight, strong under
tension and compression, flexible (to absorb torque), stiff (to resist bending and shear stress),
durable, water resistant, ventilated, heat insulated to help cool down, rust resisting and cost
effective. Because Thailand is a humid and hot place, and there is a rainy reason, our product
should be waterproofed and rust resisting, durable, heat insulated and ventilated, so that the user
won’t feel uncomfortable when wearing it and they are essential in rainy weather, especially
being durable, waterproof and rust resisting. We want our prosthetic limbs to be lightweight, but
also durable, so the user won’t feel heavy and think that it is a burden to wear a prosthetic leg.
Our prosthetic is designed to be affordable for disabled people with less income, therefore our
product should be at a reasonable price, but effective.

● lightweight
● strong under tension
● strong under compression
● flexible, to absorb torque
● stiff, to resist bending and shear stress
● durable, to resist fracture under impact
● capable of resisting stress in all planes
● cost effective
● easy to apply
● ventilated
● heat insulated
● rust resisting

Materials
Our model prosthetic legs are made of plastic to the lower the cost of the our project. However,
the real product will be made of flexible and strong materials from 3D printing, such as Flexy
Fit. Thermal plastic elastomers (TPUs) materials like Ninjaflex or Filaflex. This material will be
used to make the whole legs, but inside the socket, there will be fabric and net added to support
and reduce the friction for the user’s real legs and knees. Straps of belts or elastic bands are used
to make the socket adjustable, so that it will fit the user’s legs. Small knots will be used to make
the pylon part adjustable to the height of the user too.

Product
Analysis
At the beginning of the project, we decided to do a real model of the prosthetic leg as it would be
cost efficient and the materials would be easier to find. We felt that by making a real model, we
could control the production of the prosthetic more precisely as we handpick each material and
take part in the building process. However, we later found out that we weren’t able to make the
real model as it require molding, casting, and fabrication, all of which are above our expertise, so
we decided on 3D printing instead. The 3D printing process is less complicated, but we once
again faced a problem. We had to have a 3D file in order for the store to print it out for us. We
tried to design our model in a 3D program, but we later realized that it wasn’t working out as we
are not specialized in using it. So, we took our original design and drew them on a paper with a
more thorough measurement and mechanism. Then, we contacted the 3D printing store which
offers 3D design service and commission them to make the 3D file for us. We had to adjust a few
things, but the original design remains and the result was quite satisfactory despite the fact that
we chose to print out a miniature version of the model and limit the function of the prototype to
be cost efficient.

Conclusion
The model of the new prosthetic leg was specifically designed to be suitable for people in the
southeast asia or the hot and humid area. The materials that we suggest for the real prototype will
be heat insulator, metal, or fiber carbon so it wouldn’t get rusty. In addition, the materials will be
light and strong. The pylon are adjustable in order to fit a user’s desired height. The socket are
designed to be flexible by using straps of belts to hold the socket to the user’s leg. The outer
design of the prosthetic leg and the socket are made of heat insulator to easily cool down.

References
- Norton, K. (2007, November/December). A Brief History of Prosthetics. Amputee
coalition. Retrieved from:
http://www.amputee-coalition.org/resources/a-brief-history-of-prosthetics/
- Maroney. (n.d.). How a prosthetic leg is made!. Instructables. Retrieved from:
http://www.instructables.com/id/How-A-Prosthetic-Leg-Is-Made/
- Herr, H. (2014, March 28). New bionics let us run, climb and dance | Hugh Herr. [Video
file]. Retrieved from: ​https://www.youtube.com/watch?v=CDsNZJTWw0w
- Cyborg. (2015, November 4). Can Prosthetics Outperform Real Limbs? | Cyborg Nation.
[Video file]. Retrieved from: ​https://www.youtube.com/watch?v=a2z8CE2vomY&t=1s
- Woodford, C. (2018, February 19). Prosthetic limbs. Explainthatstuff!. Retrieved from:
http://www.explainthatstuff.com/prosthetic-artificial-limbs.html
- Prosthetics – An Education Of Artificial Limbs And Limb Replacement For Amputees.
(2009). LeTourneau Prosthetics. Retrieved from: ​https://www.llop.com/prosthetics/
- Clements, I. P. (2008, June 25). "How Prosthetic Limbs Work". HowStuffWorks.com.
Retrieved from: https://science.howstuffworks.com/prosthetic-limb3.htm
- 3D Systems. (2014, July 23). A Leg that Fits: Making Natasha's 3D-Printed Prosthetic in
Two Weeks. [Video file]. Retrieved from:
https://www.youtube.com/watch?v=l200iQJFgww
- How Much Does a Prosthetic Leg Cost?. (n.d.) Prosthetic Leg Cost. Retrieved from:
http://health.costhelper.com/prosthetic-legs.html

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