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Finite-element analysis to determine effect of monolimb flexibility on structural strength and interaction between residual limb and prosthetic socket

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Monolimb refers to a kind of transtibial prostheses having the socket and shank molded into one piece of thermoplastic material. One of its characteristics is that the shank is made of a material that can deform during walking, which can simulate ankle joint motion to some extent. Changes in shank geometry can alter the stress distribution within the monolimb and at the residual limb-socket interface and, respectively, affect the deformability and structural integrity of the prosthesis and comfort perceived by amputees. This paper describes the development of a finite-element model for the study of the structural behavior of monolimbs with different shank designs and the interaction between the limb and socket during walking. The von Mises stress distributions in monolimbs with different shank designs at different walking phases are reported. With the use of distortion energy theory, possible failure was predicted. The effect of the stiffness of the monolimb shanks on the stress distribution at the limb-socket interface was studied. The results show a trend--the peak stress applied to the limb was lowered as the shank stiffness decreased. This information is useful for future monolimb optimization.
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Published in Journal of Rehabilitation Research and Development 41(6A):pp. 775-786.
Copyright 2004 US Department of Veterans Affairs
FINITE ELEMENT ANALYSIS TO DETERMINE THE EFFECT OF MONOLIMB FLEXIBILITY
ON STRUCTURAL STRENGTH AND INTERACTION BETWEEN RESIDUAL LIMB AND
PROSTHETIC SOCKET
Winson C.C.Leea, BSc; Ming Zhanga,*, PhD; David A. Boonea, CP, BS, MPH; Bill Contoyannisb
a Jockey Club Rehabilitation Engineering Centre,
The Hong Kong Polytechnic University, Hong Kong, China
b REHABTech, Monash University, Melbourne, Australia
* Correspondence address:
Ming Zhang (PhD)
Jockey Club Rehabilitation Engineering Centre,
The Hong Kong Polytechnic University,
Hong Kong,
P.R. China.
Tel: 852-27664939
Fax: 852-23624365
Email: rcmzhang@polyu.edu.hk
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ABSTRACT
Monolimb refers to a kind of transtibial prostheses having the socket and shank molded into one
piece of thermoplastic material. It has a characteristic that the shank made of such a material can
deform during walking which can simulate the ankle joint motions to some extent. The changes of
the shank geometry can alter the stress distribution within the monolimb and at the residual limb-
socket interface, and respectively affect the deformability and structural integrity of the prosthesis
and comfort perceived by amputees. This paper described the development of a finite element model
for the study of the structural behavior of monolimbs with different shank designs and the interaction
between the limb and socket during walking. The von Mises stress distributions in monolimbs with
different shank designs at different walking phases were reported. Using distortion energy theory,
prediction of possible failure was performed. The effect of the stiffness of the monolimb shanks on
the stress distribution at the limb-socket interface was studied. The results showed a trend that the
peak stress applied to the limb was lowered as the shank stiffness decreased. The information is
useful for future monolimb optimization.
Keywords: finite element analysis, interface stress, monolimb, shank flexibility, structural integrity,
transtibial prosthesis
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INTRODUCTION
Transtibial amputees usually demonstrate some gait abnormalities such as lower walking speed (1),
increased energy cost (2) and asymmetries between legs of unilateral amputees in terms of stance
phase time, step length and vertical peak force (3). It is believed that the gait abnormalities are
mainly due to the loss of active dorsiflexion and plantarflexion motions of the ankle joint (4).
Prostheses have been designed to compensate for the loss of motions at the foot by incorporating
energy storing and releasing (ESAR) capabilities using flexible keels or shanks. The Seattle footTM
and FlexFootTM are examples of ESAR prosthetic components. Previous research suggested that
many amputees subjectively prefer ESAR prosthetic feet to conventional SACH feet on normal and
fast walking (5, 6). However, many amputees still utilize the simple SACH feet because of their
lower cost.
A “Monolimb” prosthesis design using a conventional prosthetic foot such as SACH foot perhaps is
an alternative to ESAR prosthetic feet if properly designed, providing elastic response of the shank
(7), at the same time lower the total prosthetic weight and cost. It is a kind of trans-tibial prosthesis
having the socket and the shank molded into one piece of thermoplastic material. Different names
have been used for this kind of prosthesis such as endoflex (7), total thermoplastic prosthesis (8) and
ultra-light prosthesis (9). Due to the elasticity of thermoplastics, the shank can deform leading to
simulated dorsiflexion and plantarflexion of the prosthetic foot. By proper use of material and
structural design, it is possible that the shank deformability may be altered such that natural ankle
joint motions are mimicked. At the same time, structural integrity should be maintained without
permanent deformation and buckling of the prosthesis. Changes of shank flexibility may alter the
stress distribution at the prosthetic socket-residual limb interface which is related to the comfort
perceived by the amputees (10). Up to now there is no clear guideline on the shank designs of
monolimbs. In order to optimize the design of monolimb and maximize comfort, comprehensive
understanding of the deformation and stress at the shank of the monolimb during walking and the
effect of the shank flexibility on stress distribution at the interface between socket and limb are
essential.
In general there are two approaches to investigate the shank deformation and its effect on socket-limb
interface stress: experimental measurements and theoretical analyses. Experimental measurements
require the use of stress/strain sensors attached to appropriate positions of the shank and the socket
inner surface. Theoretical analyses such as finite element (FE) methods, which have been widely
used in lower limb prosthetics in the past decade, can be useful to study the deformations and
stresses. The advantage of the use of FE analysis is that stress, strain and motion in any parts of the
model can be predicted and parametric analyses can be performed easily without the need to fabricate
prostheses. In previous FE models, focus was put on investigating into the variation of stresses
distributed at the limb-socket interface under different socket modifications (11, 12), material
properties of the sockets (11, 13) and liners (14) and frictional properties at the interface (15). The
deformability of the prosthesis and the effect of shank deformation on interface stresses, however,
received little attention.
The aim of this paper is to describe the development a FE model which was used to study the
interface stress between the limb and socket, shank flexibility and possible failure of the prosthesis.
Different shank geometries were used and their effects on limb-socket interface stresses were studied.
METHODS
A FE model was developed for a right-sided unilateral transtibial amputee subject to determine the
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stresses in the monolimb during walking and the effect of the shank stiffness on interface stresses at
the limb-socket interface. The subject was 55 years old and 81kg in weight who have experience in
using monolimbs. Contact between the limb and the socket was simulated considering pre-stress
when the limb was donned into a shape-modified socket and friction/slip using automated contact
technique. Our previous FE analyses have showed the importance of the consideration of pre-stress
in predicting interface stresses at loading stage (16,17). Proximal region of soft tissue and the bones
were fixed, and loading was applied at the prosthetic foot according to gait analysis data (17-19).
Geometries
The geometries of the bones and their positions relative to the limb surface were obtained from
magnetic resonance images (MRI) on the subject. Outlines of bones were identified in Mimics 7.1.
The residual limb surface was obtained by digitizing a loose plaster cast using the BioSculptorTM
system. Bone geometries were assembled into the residual limb according to the MRI. A prosthetist
using ShapeMakerTM 4.3 prepared the geometry of the monolimb, by applying built-in, shape-
rectification template, as shown in Figure 1, to the digitized limb surface and aligning a shank and
blending smoothly to the socket end. Different geometries of shanks (Figure 2) were designed for
analysis. The whole monolimb was assigned 4 mm thickness. The geometry of the prosthetic foot
was based on direct measurement of a Kingsley SACH foot (length 250mm) and was added to the
distal end of the shank. The foot was partitioned into two regions: the wooden keel, and the
surrounding rubber foam. Although the shank geometry was varied in different designs, the relative
positions of the prosthetic foot to the socket were the same. The model in its entirety, as shown in
Figure 3a, was exported to ABAQUS version 6.3 (Hibbitt, Karlsson & Sorensen, Inc., Pawtucket,
RI). A FE mesh with 3D tetrahedral elements were built using ABAQUS auto-meshing techniques.
The number of elements assigned varied among different monolimb designs ranging from 37,836 to
38,565.
Material properties
In this preliminary study, the mechanical properties of the materials were assumed to be linearly
elastic, isotropic and homogeneous. The estimated Young’s modulus was 200kPa (15) for soft
tissues and 1500MPa (20) for the monolimb structure following the mechanical property of
polypropylene homopolymer. Poisson’s ratio was assumed to be 0.45 for soft tissues and 0.3 for
monolimb. The prosthetic foot was partitioned into a keel region and surrounding rubber foam and
were assigned Young’s moduli 700MPa and 5MPa respectively. Poisson’s ratio was assumed to be
0.3 for the two regions of the prosthetic foot.
Boundary conditions and analysis steps
The four bones were given fixed boundaries. Fixed boundary was also given to proximal region of
the soft tissue as shown in Figure 3. The fixed region of the soft tissue was away from the socket so
that the boundary condition would not have significant effect on interface stresses. The bones and
soft tissues were modeled as one body with different mechanical properties. The residual limb and
socket were modeled as two separate structures and their interaction was simulated using automated
contact methods. The distal surface of the shank and the top surface of the prosthetic foot were tied
together by rigidly connecting the nodes between the two surfaces where they contact. For
simplification, it was assumed there was no foot clamp adaptor holding the shank onto the prosthetic
foot.
There were two phases in the analysis. The first phase was to simulate the interaction produced by
donning the limb into the prosthetic socket. At this phase, the external surface of the monolimb
together with the bones and the soft tissue around the femur were fixed. Initially, some regions of the
limb penetrated into prosthetic socket, as shown in Figure 3b, because of the socket rectification.
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Automated contact method was employed and the solver in ABAQUS automatically moved the
penetrated limb surface onto the inner surface of the socket. Stresses were developed on both the
inner surface of the socket and the residual limb over the overlapped regions (16,17).
At the second phase, the pre-stresses and the deformations calculated in the first phase were kept.
The fixed boundary constraint previously added to the external surface of the monolimb was
removed. External loadings were applied at the prosthetic foot to simulate the participating subject
walking. Stiffness changes upon large deformations, known as geometrical nonlinearity, were
considered. Three load cases were applied separately at the centers of pressure on the plantar surface
of the foot according to gait analysis data of the same amputee (18, 19) to simulate heel strike,
loading response and heel off of gait. The three loading conditions were respectively 8%, 19% and
43% of stride. The center of pressure was obtained by projecting the positions of center of pressure
calculated on the force platform onto the plantar surface of the foot. Kinematic data of the limb and
monolimb and ground reaction forces were obtained from the Vicon Motion Analysis System and a
force platform respectively. The magnitude, position and direction of the applied load were listed in
Table 1. The loadings were assumed to be the same for different shank designs at the same loading
conditions. This assumption was based on previous research showing that the ground reaction forces
varied little with the use of different stiffness of prosthetic feet (21, 22). Coefficient of friction (
μ
) of
0.5 was assigned for socket-limb interface (15, 23). Sliding was allowed only when the shear stress
at the interface exceeded the critical shear stress value τ > τcrit =
μ
p, where p is the value of normal
stress. The analysis was performed with different shank designs of the monolimb as shown in Figure
2.
RESULTS AND DISCUSSIONS
Figure 4 shows the von Mises stress distribution in the monolimb with circular shank (design A
shown in Figure 2) over the three loading conditions. At heel strike and loading response, peak von
Mises stresses fall on the antero-proximal region of the shank. Whilst at heel off, peak von Mises
stresses fall on the antero-distal region of the shank. The stresses are smaller at heel strike because
of the lower ground reaction forces and shorter moment arm from the load line of the ground reaction
force to the shank, and reach the highest, which is 11.2 MPa for design A, at heel off. Using
distortion energy theory, which is widely used in predicting failure of ductile materials (24), failure is
predicted to occur if the von Mises stress is equal to or greater than the uniaxial failure stress. Yield
stress of polypropylene homopolymer, which is 35MPa (20), is considered to be the uniaxial failure
stress based on the fact that the design of monolimb is deemed unacceptable if the permanent
deformation occurs changing the alignment of prosthetic foot relative to the socket. As the peak von
Mises stresses are much lower than the yield stress of the thermoplastic material, failure is predicted
not to occur during level walking for that design. Table 2 shows the values of prosthetic foot
dorsiflexion angles. Foot dorsiflexion angles are defined in this paper as the angle changes between
the transverse plane and the flat surface of the prosthetic foot attached to the shank (Figure 5) after
external loadings were added. The “foot dorsiflexion angles” takes into account the motions of the
prosthetic foot due to deformation of the shank and the movement of the whole monolimb with
respect to the residual limb. For monolimb design A, the prosthetic foot dorxiflexes to 4.2 degrees at
heel off which is much lower than the normal foot dorsiflexion angle at around 10 degrees (25)
during the period of heel off.
From the above results, there is space for the increase in shank flexibility as the peak von Mises
stresses were much lower than the yield stress of the material, the shank appears rigid for the circular
shank having 48mm outer diameter and previous research showed that shank flexibilities can enhance
gait performance (7, 9). Shank flexibilities were altered in this study by changing the cross sectional
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geometry of the shank as shown in Figure 2. Table 2 shows the locations of peak stress at the shank
and compares the magnitudes of peak von Mises stresses and foot dorsiflexion angles among
different shank designs at the three loading conditions. Reducing the antero-posterior dimension of
the shank at the distal end (design B) leads to increases in flexibility of the shank. High von Mises
stresses (Table 2) and major deformation (Figure 5a) occurs at the distal end of the shank of
monolimb design B at loading response and heel off. The peak von Mises stress for design B
increases to 30.8 MPa (Table 2) at heel off which is predicted to be lower than the yield stress of the
material and hence the design meets the strength requirement. Further investigation is required to
look into the fatigue life of the monolimb under this stress level. Foot dorsiflexion angle reaches
11.5 degrees comparable to that of normal foot at heel off. The increase in foot dorsiflexion angle at
heel off could be the main contribution on the improved gait efficiency using prosthesis with flexible
shank as suggested by previous researchers (7, 9, 26). Reducing the antero-posterior dimension of
the shank at proximal end forming a uniform cross sectional elliptical shank (design C) gives further
increase in the flexibility. However, some material yield is predicted to occur at heel off for the
elliptical design as it is estimated that the peak von Mises stress was slightly greater than 35 MPa.
Figure 5b shows the predicted deformation of monolimb design C.
It is noted that the measurement method of ankle motion used in this study was not same as the one
used in gait analysis. Ankle motion was described in this study by the angle changes of the top
surface of the solid wooden keel of the prosthetic foot in the sagittal plane. This measurement
method placed emphasis on the motion of the prosthetic foot due to shank deflection which was the
primary interest of this study. The measured foot motion was apparently unaffected by the
deformation of the rubber foam at the plantar region of the prosthetic foot and the possible motion
between the shoe and the foot. In gait analysis, ankle motions are commonly measured according to
the reflective markers attached to the prosthesis and the shoe. Motion of the foot-shoe complex and
the compression of the rubber foam could both contribute to the foot motion.
Previous gait analysis studies show a brief external plantarflexion moment early in the stance phase
as the line of action of the ground reaction force passes posterior to the ankle joint, followed by
dorsiflexion moment when the ground reaction force shifts anteriorly (25). The results in this study,
however, show that the prosthetic foot dorsiflexed at all the three loading conditions. At heel strike,
the line of action of the ground reaction force as usual passes posterior to the ankle joint which tends
to plantarflex the prosthetic foot. However, as the force line passes anterior to the proximal shank
and the knee joint, the foot dorsiflexion angle, defined as the angle changes between the transverse
plane and the flat surface of the prosthetic foot attaching to the shank, is positive given the
deformability of the shank as well as the motion of the monolimb relative to the residual limb. The
magnitudes of the dorsiflexion angles are small at heel strike for the three monolimb designs.
Another important aspect of this study is to investigate the stress distribution at the limb-socket
interface with varying monolimb flexibility. Figure 6 shows the normal stress distributions of the
limb at heel strike, loading response and heel off using the monolimb design A. High pressure falls
on mid-patellar tendon (MPT), anterolateral tibia (ALT), anteromedial tibia (AMT) and popliteal
depression (PD) regions where socket undercuts were made. The three loading conditions caused
extension of the monolimb relative to the residual limb. The extension moment is consistent with
previous gait study showing that transtibial amputees demonstrated an external knee extension
moment almost throughout the stance phase of the gait as they tended to move the body center of
mass more anteriorly (27). Due to the extension moment of monolimb and the inward budge of the
patellar bar, the stresses are greater in patellar tendon region than popliteal depression region. The
presence of laterally directed ground reaction force (26) explains the higher pressure in anterolateral
tibia than anteromedial tibia regions. High resultant shear stress, which is the combination of
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longitudinal and circumferential components of shear stresses in the plane of contact interface, is
predicted at the four critical regions with socket undercuts. The peak stresses predicted in the FE
model are in the range of the clinical measurements (28, 29).
The patterns of the normal and shear stress distribution are similar among the three different shank
designs at the same loading conditions but differ in peak stress values. Figures 7 and 8 compare the
peak normal and resultant stress distribution over the four critical areas among different shank
designs. There is a tendency that increases in shank flexibility led to general decreases in peak
stresses applied onto the residual limb. The tendency could be explained from a total energy point of
view. Deformation of the prosthesis absorbs some energy, just like ESER prosthetic foot absorbing
some potential energy, causing the reduction of the energy actually transferred to the residual limb.
The magnitude of stresses applied onto the skin surface of the residual limb are related to comfort
perceived by amputees (10). The reduction of stresses could explain improved comfort of using
prosthesis with flexible components (7, 9, 11).
It was assumed in the model that the soft tissue was a passive structure. However, in the real case the
muscles at the residual limb would have some degree of contractions during walking. Muscle
contractions leading to stiffness changes at different regions of the limb could alter the stress
distribution at the limb-socket interface. Little is known about the effect of muscle contractions on
interface stresses because most FE models did not consider muscle contraction (11-15). The
inclusion of muscle contraction in FE model requires the investigation of the timing and intensity of
muscle contraction at the residual limb during walking, the relationship between muscle contraction
and stiffness, and the muscle geometry from imaging data. The difference in prediction of interface
stress between a passive soft tissue structure and a soft tissue with muscle contraction deserves
further investigation.
As far as the fabrication method is concerned, monolimb is traditionally fabricated by drape molding
a heated thermoplastic sheet onto the model composed of a shape-modified residual limb plaster
model and a pylon giving the shape of socket and shank of the monolimb (7,9). A liner can be added
within the socket which could help distribute stresses more evenly at the limb-socket interface and
closing the “hole” at the distal end of the socket. However, a liner could produce some problems
such as hygiene problems (sweat absorbing) and requirement of frequent maintenance. We have
some experience of fitting patients with monolimbs which do not have liners and do not encounter
major fitting problems. For those reasons a liner was not added in this FE model. Under this
fabrication method, the wall-thickness of the thermoplastic material is almost uniform. Adjusting the
cross-sectional geometry of the shank of a monolimb appears to be the most effective method of
altering the flexibility of the monolimb.
It is possible the fabrication processes be performed using computer-aided design/computer-aided
manufacturing (CAM/CAM) system. The residual limb shape can be digitized, and socket shape-
modification and positioning of the shank can be designed in a prosthetic CAD software, such as
ShapeMakerTM (30). The CAD data can then be sent to a rapid prototyping machine for fabrication.
The use of rapid prototyping machine to fabricate prosthetic socket have been reported in the
literature (31, 32). Using CAM/CAM technique, monolimbs can be fabricated with tailored varying
wall thickness and geometry of the shank. However, this fabrication method is much expensive.
In future studies, improved characterization of material properties of soft tissues and interface contact
conditions between the skin and the socket will be pursued. Gait analysis and clinical measurement
of the stresses at the limb-socket interface and prosthesis will be performed to validate the model.
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Fatigue life of monolimbs under repeated loading will be investigated. The FE models will be served
as an important tool in the process of optimizing prostheses with flexible shanks. Further parametric
analysis of the model will be performed for the optimization.
CONCLUSION
Little has been suggested about the design of monolimb due to the lack of understanding of the
deformation and strength of the shank under loading, and the effect the shank deformability on
comfort. In this study, a finite element model was developed which can contribute to 1) the
prediction of shank deformability of monolimbs during walking without actual prosthetic fitting and
direct measurement 2) the prediction of stress distribution at the shank and the inspection of possible
failure of the prosthesis which serves as a reference for future monolimb design and optimization,
and 3) the better understanding of the effect of shank flexibility on socket-limb interaction. The
improved understanding of monolimb structural behavior could promote further optimization of the
design of monolimbs.
ACKNOWLEDGEMENTS
The work described in this paper was supported by The Hong Kong Polytechnic University Research
Studentship and a grant from the Research Grant Council of Hong Kong (Project No. PolyU
5200/02E).
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Table 1. Three loading conditions analyzed in the FE model
Loading
conditions
(% of stride)
Vertical
force (N) Antero-
posterior
force (N) *
Medial-
lateral force
(N) #
Center of
pressure
distance from
back of the
heel (cm)
Heel strike (8%) 480 -67 -10 5.3
Loading
response (19%) 946 -143 69 12
Heel off (43%) 804 57 65 17.3
* positive value indicates anterior-directed force
# positive value indicates lateral-directed force
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Table 2. Comparisons of peak von Mises stresses and foot dorsiflexion angles among three different
shank designs at three loading conditions
Location of the
shank having peak
von Mises stress
Peak von
Mises
stress
(MPa)
Foot
dorsiflexion
angle
(degrees)
Design A Anterior-proximal 3.2 0.5
Design B Anterior-proximal 4.4 2.0
Heel
strike Design C Anterior-proximal 6.9 2.2
Design A Anterior-proximal 8.8 2.7
Design B Anterior-distal 18.0 5.2
Loading
response Design C Anterior-proximal 27.2 12.2
Design A Anterior-distal 11.2 4.2
Design B Anterior-distal 30.8 11.5
Heel off Design C Anterior-distal 36.7 16.3
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CAPTIONS
Figure 1. Socket rectification template. Patella (Pa), patellar tendon (PT), fibular head (FH),
anteromedial tibia (AMT), anterolateral tibia (ALT), tibial crest (TC), fibular end (FE), tibial end
(TE) and popliteal depression (PD) are the regions where rectifications were applied. The numbers
shows the maximum depth/height (in millimeter) of undercuts (negative values) or build-ups
(positive values) over the regions.
Figure 2. Three different shank designs analysed in the FE model. Design A – circular shank with
outer diameter 48mm; Design B – proximal end of the shank being circular with outer diameter
48mm, the cross section becoming elliptical towards the distal end as the anteroposterior dimension
linearly reduced to 28mm; Design C – elliptical shank with outer diameter 28mm.
Figure 3. (a) Geometries of bones, residual limb, monolimb and prosthetic foot; (b) Closer look at the
residual limb-prosthetic socket showing that some regions of the undeformed residual limb
penetrated into the socket due to socket rectification.
Figure 4. Von Mises stress distribution at the monolimb with the 48mm diameter circular shank
(design A) at (a) heel strike, (b) loading response and (c) heel off.
Figure 5. Deformation of shank of (a) design A, and (b) design B at the three loading conditions.
Figure 6. Anterior and posterior views of normal stress distribution at (a, b) heel strike, (c, d) loading
response and (e, f) heel off using monolimb with 48mm diameter circular shank
Figure 7. Comparison of normal stress distribution at mid-patellar tendon (MPT), anterolateral tibia
(ALT), anteromedial tibia (AMT) and popliteal depression (PD) regions at the instance of (a) heel
strike, (b) loading response and (c) heel off using the three different shank designs
Figure 8. Comparison of shear stress distribution at mid patellar tendon (MPT), anterolateral tibia
(ALT), anteromedial tibia (AMT) and popliteal depression (PD) regions at the instance of (a) heel
strike, (b) loading response and (c) heel off using the three different shank designs
13
Figure 1
14
Figure 2
183mm
341mm
48mm
Uniform cross
section over
the shank
Design A
A
nterio
r
Posterior
Design B
Shank proximal
end
48mm
48mm
28mm
Shank distal
end
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28mm
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section over
the shank
Design C
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nterio
r
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183mm
341mm
A
nterio
r
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341mm
15
Figure 3
Patellar tendon
Popliteal
depression
Bones Prosthetic socket
Residual limb
Residual limb
Bones
Monolimb
Prosthetic foot
(a) (b)
Loading added
at the plantar
surface of the
foot
Proximal region
of the limb given
fixed boundary
16
(a) (b) (c)
Figure 4
3.2MPa 8.8MPa 11.2MPa
17
Figure 5
Heel strike Loading
response Heel off
Heel strike Loading
response Heel off
(a)
(b)
5.2 degrees
11.5 degrees 16.3 degrees
12.2 degrees
Dorsiflexion
2 de
g
rees
Dorsiflexion
2.2 de
g
rees
18
Figure 6
(a) (b)
(c) (d)
(e) (f)
A
nterior view Posterior view
287 kPa
123 kPa
70 kPa
142 kPa
370 kPa
337 kPa
82 kPa
152 kPa
354 kPa
206 kPa
74 kPa
177 kPa
MPa
MPa
MPa
Heel strike
Loading
response
Heel off
19
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Regions
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Design C
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MPT ALT AMT PD
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Figure 7
20
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MPT ALT AMT PD
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(c) Heel off
Figure 8
... The finite element (FE) method is a useful tool to evaluate the structural integrity of prosthetic sockets. Its applicability to transtibial sockets has been shown in computational studies that used FE to evaluate the structural strength of new socket designs and to determine optimal design parameters [12][13][14][15][16][17][18][19][20]. In the current study, we developed an FE model of our socket design to determine the structural behaviour of the socket wall. ...
... Several studies have used finite element models to evaluate the structural strength of transtibial sockets [11][12][13][14][15][16]. However, the load cases used in these studies differ greatly. ...
Article
Full-text available
Background: Participants in Sierra Leone received a Fused Filament Fabrication (FFF)-printed transtibial prosthetic socket. Follow-up was conducted on this group over a period of 21 months. To investigate the failure of some of the FFF-printed transtibial sockets, further strength investigation is desired. Methods: A finite element (FE) analysis provided an extensive overview of the strength of the socket. Using follow-up data and FE analyses, weak spots were identified, and the required optimization/reinforcement of the socket wall was determined. Results: Five sockets with a 4 mm wall thickness were tested by five participants. The strength of the 4 mm prosthetic socket seemed to be sufficient for people with limited activity. The 4 mm sockets used by active participants failed at the patella tendon or popliteal area. One socket with a wall thickness of 6 mm was used by an active user and remained intact after one year of use. An FE analysis of the socket showed high stresses in the patella tendon area. An increased wall thickness of 7 mm leads to a decrease of 26% in the stress corresponding to the observed failure in the patella tendon area, compared to the 4 mm socket. Conclusions: Follow-up in combination with an FE analysis can provide insight into the strength of the transtibial socket. In future designs, both the patella tendon and popliteal area will be reinforced by a thickened trim line of 7 mm. A design with a thickened trimline of 7 mm is expected to be sufficiently strong for active users. Another follow-up study will be performed to confirm this.
... The deformability of shank was predicted during walking without the actual pro fitting of the prosthetic and direct measurement. The effect of shank flexibility on socket-limb interaction was explored [22]. A FE model and a concurrent multibody of the femur, tibia, socket and ESAR prosthesis of a transtibial amputee was formed [23].The effect of friction on the residual limb of the transfemoral amputee was studied through FEM model. ...
... David A. Boone et al. [22] The evolution of finite element model was described and theaction of mono-limbs structurally with various shank blueprints were analyzed, the interplay of the residual leg and the socket was also studied during regular movement such as while walking. ...
Article
Full-text available
Finite element analysis (FEA) is used to study the characteristics of various objects in different working condition for imitating real life like scenarios. The present work describes an overview of FEM simulations for lower limb prosthetics. The review will give a deep insight for stress interface and load distribution on the residual limb. It enables prosthetists to design the socket for effective functional performance. The study suggests that outcomes through FEA simulations under test conditions is needed It has been observed that predicted outcomes using FEA were in agreement with the experimental measurements. Further, the study suggests that outcomes of the FEA analysis under test conditions may be validated through GAIT cycle.
... These innovative devices have revolutionized the field of assistive technology, enabling amputees to engage in sports and physical activities that were once deemed unattainable (13,29). blades, which showed a good agreement between experimental and numerical results. ...
Article
Full-text available
This study focuses on the development of a reliable prosthetic running blade primarily composed of carbon fiber. The reliable performance of novel prosthetic running blades has been evaluated by mechanical testing and finite element numerical modeling. The experimental analysis confirmed that these blades exhibit superior suitability for high-impact activities, demonstrating reliable load-bearing capacity and effective shock absorption properties. The tensile testing exhibited a linear elastic behavior of the composite material up to a strain of 0.075 mm/mm. Further, it was found that stress concentration areas and fracture points within the blade structure. Furthermore, numerical results revealed a maximum deflection of 29.60 mm that the blade can achieve. The kinetic energy loss during impact demonstrated an 8.5% decrease in blade kinetic energy, with the highest loss occurring at Vy = 30 m/s. Ultimately, this research aims to enhance the reliability, durability, and safety of prosthetic running blades, empowering athletes to reach new heights in sports.
... Stewart and Brown [5] worked on the crack growth problem using FEM by building a model to determine the expected life for the pylon of a given prosthetic: they thus investigated fatigue failure and the stress distribution for the pylon adapter, and the model was compared to manufacturer's testing figures and cyclic testing. Lee [6] studied the stiffness effect for three different forms of monolimb pylon (elliptical, circular, and a third type where one end of the pylon was circular while the cross-section became elliptical at the other end) by using FEM to examine the stress distribution at the socket interface during walking. In this context, the monolimb refers to a moulded single piece made from thermoplastic materials covering both socket and shank. ...
Article
Full-text available
The standard prosthetic pylon is commonly manufactured of lightweight metals such as aluminium. In this study, two types of pylons were manufactured. The first pylon (I) was made with one suggested combination, which consists of layers of 2 perlon, 3 carbon fibre, and 2 perlon, while the other pylon (II)was made with a second suggested combination, with layers composed of 2 perlon, 3 glass fibre, and 2 perlon, with both used as reinforcement materials for an orthocryl (617H19) laminate matrix. A vacuum bagging technique was used in the manufacture of both samples.Various mechanical properties such as the modulus of elasticity, tensile strength, and percentage elongation were measured for the two samples by means of tensile testing. Buckling tests were also performed for the two pylons made of composite materials and an example of the currently used metallic pylon in stainless steel; these tests were intended to investigate the critical load and maximum deflection for each pylon, and the maximum critical load, equal to 44 KN, was seen in pylon (I) while the maximum deflection, equal to 1.5 mm, occurred in pylon (II).Using the finite element method (FEM) in ANSYS WORKBENCH 17.2, the maximum deformation, Von-Mises elastic strain, equivalent Von-Mises stress, critical buckling stress, and the buckling mode shape for both composite pylons and the metallic pylon were also analysed.Validation of the experimental results of the buckling test was acquired by comparing them with the numerical results; this supported the effectiveness and accuracy of the FEM simulated model, based on excellent agreement between the results, where as the discrepancy percentage did not exceed 3.01%.
... Nevertheless, subjects reported more convenience, more speed and more flexible during walking. Moreover, the results showed that the effect of flexibility of prosthetic foot on the GRF was contrary to that of pylon [11]. Recently, researchers have designed new components that have shock-absorbing property such as telescoping pylon for prosthesis. ...
Conference Paper
Full-text available
A suitable prosthesis possesses appropriate stiffness and damping property which can decrease the magnitude of transient forces which exert on a patient"s lower limb amputated during walking. In more cases, the effectiveness of mechanical properties prosthetic components has been investigated separately in the literature. In order to quantify investigate different prosthetic feet and pylons an optimization method was implemented in the dimensionless objective function which is driven from motion equations of 5-Degree-Of-Free (DOF) mass-spring-damper model. The optimization method was used to find a region including the best Elasto-damping parameters of the pylon as well as the spring and the damper coefficients of the prosthetic foot which can significantly attenuate the shock loads of transient forces. As a result, the optimized region was introduced as a safe region where the values of the objective function were minimized. In addition, the results of this study showed a correlation between the Elasto-damping parameters of the pylon and the mechanical properties of prosthetic feet.
... Some researchers modeled the entire volume of the stump soft tissues (excluding the bones) as a homogeneous non-linear hyperplastic deformable material [172,184], others used the non-linear viscoelastic model [185], whereas some developed a detailed model based on MRI data [104,186]. Most of the FE studies simplify the stump soft tissues as a homogenous linear elastic material [73,171,180,[187][188][189][190]. Colombo et al. [191] verified the use of the simplified linear model by the fact that it gave them similar results compared to the hyperplastic model with the potential energy of deformation expressed by a second-order polynomial, but its calculation time was 400% faster. ...
Thesis
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.
Article
A lower-limb prosthetic socket is the custom-made structural element interfacing the residual limb of a person with an amputation to their prosthetic leg comprising off-the-shelf componentry. The socket can be subject to mechanical failure, especially when new fabrication methods and materials are introduced (e.g. 3D printing). Failures can have severe consequences for patients. A systematic review was conducted to collect information about available socket mechanical testing methods, to support the definition of widely accepted guidelines. To this aim the structural testing methods were reviewed, but not the results of the individual studies. 729 records were retrieved, of which 16 articles were included. No articles addressed transfemoral socket testing, as all focused on transtibial sockets. Thirteen articles used some sort of adaptation of ISO 10328, and all of them simulated the toe-off instant of gait, with load level acceptable for patients from 100 to 125 kg of weight. Ten considered a rigid limb dummy. Overall, ISO 10328 appears as a viable starting point for defining a testing guideline, but a considerable number of details has to be agreed upon, starting from clear definitions of anatomical landmarks and socket axes, which are required to implement a representative and repeatable test method.
Chapter
The sockets are generally made from carbon fiber which makes them cost high. Replacing carbon fiber with a more ecological and socio-economical fiber such as Alfa fiber can considerably reduce the cost. The objective of this paper is to develop and validate a numerical finite elements virtual prototype that can be used for prosthesis design. An experimental bench is developed to measure the pressure between a residual limb and a trans-tibial prosthetic socket. Three finite element models are created and compared to experimental results. The numerical results from the virtual prototypes show a good correlation with the experimental results in fact the predictability is equal to 96.62%. Based on these results, the virtual prototype can be adopted to design resistant and comfortable trans-tibial prosthetic sockets. In the final part of the paper, a fatigue analysis is made. The fracture is observed on the first cycle and it is a ductile failure. The socket reinforced by ALFA fibers does not meet the static and fatigue requirements of ISO 10328 for the test failure, in fact required resisting force Fsu is equal to 3019N in the case of a ductile failure but the measured failure force is ~2700N. The failure occurred on the junction; no cracks appeared in the body of the socket. The junction can be studied and reinforced with a better strategy.
Article
Polypropylene Co-polymer (PPCP) Prosthetic Foot Model, Indigenously designed at All India Institute of Physical Medicine and Rehabilitation (AIIPMR), Mumbai. More commonly, this design is known as Modified Flex foot. Various researcher’s contributed towards its design modification, material optimization, patient trial & clinical implications and further improvements. As such, this study was conducted to observe & understand the stress analysis of this modified flexfoot under loading conditions at various orientation of gait. Finite element analysis (FEA) method was used with Ansys 12.0 software. Study objectives was to construct and analyze the finite element model, to find out & understand failure prone areas in the present design of PPCP prosthetic foot. This study was conducted into five phases. At initial phase, actual foot design was constructed and input parameters like geometrical parameters were calculated considering the standard length transtibial amputee. Similarly Material properties, loading conditions & boundary conditions were determined. AutCAD model was constructed using input parametrs & imported into Ansys 12.0 software. Finite element model were constructed and analyzed. Results were noted, which were displyed in the form of several contour plots & through colours that correspond to different stress values. FEA results obtained for various stress values like, Elemental stress, shearing stress & Von Mises stresses (Combination stresses). Peak Von Mises stress value of 28112 Mpa, observed at lower ankle fillet region during heel strike orientation of the gait. Study concluded that lower ankle fillet region & Midfoot spring region will be subjected to maximum stress during heel strike, Mid stance & push off. It was concluded that lower ankle fillet region & Midfoot spring region will be subjected to maximum stress during heel strike, Mid stance & push off.
Article
This is a report on experience gained since publication of the article by Wilson and Stills in the March 1976 issue of 'Orthotics and Prosthetics' on ultralight prostheses for below-knee amputees made by vacuum-forming sheet polypropylene. The design resulted in a prosthesis that weighs one-third of the more conventional PTB prosthesis, with essentially the same function, depending upon the treatment of the sole and heel. In addition to offering the possibility of a decrease in energy requirements, suspension problems might be reduced. The following general conclusion can be drawn from this preliminary data: Although wearing time and walking distance do not appear to increase when the lighter prosthesis is used the overwhelming majority of the subjects felt that the lighter prosthesis requires less energy to walk with than a conventional prosthesis. Opinions were mixed regarding which prosthesis is easiest to control and which one was the most comfortable to walk on. In both cases, however, the majority favored the experimental prosthesis. The overall preference was overwhelming for the ultralight prosthesis. The two who preferred their conventional prosthesis both liked the lightness of the experimental prosthesis, but they were very dissatisfied with the foot action. There were six incidences of structural failure. Three were fractures of the polypropylene at the toe area of the foot. Two other cases involved crushing of the internal keel foot.
Chapter
A method of fabrication of an ultralight below-knee prosthesis is presented. Experiences with eight subjects in the experimental study are included.
Article
The traditional way of making a prosthetic socket is by draping a heated thermoplastic sheet over the positive mould, or by applying layers of woven materials together with acrylic resins over the positive mould. This process is extremely labour intensive, and it usually takes two to three days to make one socket. This paper presents the development of a prosthetics Computer-Aided-Manufacturing (CAM) system that utilises Rapid Prototyping (RP) technology. The system reduces the socket making time from days to less than 4?h. Clinical and biomechanical studies are conducted to evaluate the comfort and fit of the new socket during gait. Preliminary investigation of the new socket shows that its functional characteristics are very similar to that of a traditional socket
Article
This study evaluated the mechanics of the knee during gait in persons with trans-tibial amputations. Spatiotemporal, kinematic, kinetic, and electromyographic data (EMG) were collected from ten individuals with trans-tibial amputations and ten control subjects during level walking. Results found that the trans-tibial amputee (TTA) group had significantly greater EMG activity of the knee extensors and knee flexors compared to normal. The muscle action of the TTA group was inconsistent with the knee kinetic data as demonstrated by a minimal external knee flexion moment and negligible knee power. The discrepancy between the mechanical and physiological measures of knee demand in this population illustrates the need for an integrated approach for the study of joint function during gait (i.e. EMG in combination with kinetic measures).
Article
Monolimb refers to a kind of trans-tibial prosthesis having the socket and the shank molded into one piece of thermoplastic material. It has a characteristic that the shank could deform during walking. Positive feedbacks were gained including better comfort and improved gait efficiency from patients using prostheses with deformable shanks (Valenti, 1991; Coleman et al., 2001). By proper use of material and structural design, the shank flexibility could be raised which might further improve comfort and gait. However, structural integrity should be remained which resists buckling of the prosthesis. Finite element (FE) analysis has been used in lower limb prosthetics in the past two decades. The advantages of using FE analysis are that stress, strain and motion in any parts of the model can be predicted and parametric analyses can be done easily. In previous FE models, focus was put at the socket-limb interface. In this investigation, FE analysis was applied to study the stress distribution at the residual limb and monolimb. Prediction of interface stress, shank flexibility and possible failure could be made in this model. Once validated, different parameters will be input for design optimization.