Enhancing the Strength of 3D-Printed Polymer Exoprosthetic Socket by Localized Non-Planar Continuous Carbon Fiber Reinforcement

Abstract

This study investigates strategies to enhance the structural integrity of 3D-printed orthopedic transtibial exoskeleton sockets by integrating non-planar reinforcement with structured prepreg rods composed of continuous carbon fibers, leveraging multi-axis additive manufacturing techniques. A prototype of a cylindrical polyamide 3D-printed exoskeleton socket is examined. Numerical modeling using progressive failure analysis, incorporating material property degradation models, successfully simulated damage accumulation in the studied 3D-printed structures. Numerical simulations revealed that crack formation initiates in the socket’s distal section, aligning with physical test observations. Targeted localized reinforcement with carbon rods effectively strengthened the high-load regions of the prosthetic devices. A method to improve product strength by optimization of the internal architecture of the embedded reinforcements in the local stress concentrator zones is proposed. The results demonstrate a reduction in stress concentrations within prostheses when using carbon fiber reinforcements. Multi-axis dual extrusion non-planar additive manufacturing techniques were used to produce the developed prototypes. Surface morphology was examined, and optimal process parameters were determined to enhance printing quality. The developed approach enables precise reinforcement of custom-shaped sockets with complex geometries.