Evolving 3D-Printing Strategies for Structural and Cosmetic Components in Upper Limb Prosthesis

• Published in: Prosthesis (Basel, Switzerland) Vol. 5; no. 1; pp. 167 - 181
• Main Authors: Manero, Albert, Sparkman, John, Dombrowski, Matt, Smith, Peter, Senthil, Pavan, Smith, Spencer, Rivera, Viviana, Chi, Albert
• Format: Journal Article
• Language: English
• Published: Basel MDPI AG 01.02.2023
• Subjects: Additive manufacturing; aesthetic design; Aesthetics; Confidence; Design; Designers; Electromyography; Pediatrics; Precision medicine; Prostheses; Rapid prototyping; Skin; Social isolation; thermoforming
• ISSN: 2673-1592; 2673-1592
• DOI: 10.3390/prosthesis5010013

The evolution of prosthetic limbs continues to develop, with novel manufacturing techniques being evaluated, including additive manufacturing. Additive manufacturing (AM), or 3D-printing, holds promise for enabling personalized and tailored medical device options. The requirements for personalized medicine, coupled with the limitations of small-batch manufacturing, have made the technique viable for exploration. In this manuscript, an approach is presented for incorporating additive manufacturing for prostheses, both as a final part and in applications as an intermediate manufacturing step. As a result, through the use of these methods a multi-gesture capable electromyographic prosthesis was designed and manufactured, currently being evaluated in clinical trials for pediatric patients. This paper explored the results of this unique method of applying additive manufacturing techniques, and assessed how the blend of different manufacturing techniques improved performance and reduced device weight. Creating unique and aesthetic cosmetic coverings for the device was achieved through using additive manufacturing as an intermediate manufacturing component and, then, applying thermoforming. Cosmesis components saw a 33% reduction in weight from this change in manufacturing. The approach is explored to blend multiple manufacturing techniques to create cosmesis components and structural components for the prosthesis. The techniques serve the design intent to reduce reported challenges with upper limb prosthesis devices and to encourage device retention. Recommendations for manufacturing strategies are discussed, including the limitations.