Additive manufacturing of a transtibial prosthetic socket through a FE-based topology optimization approach

The present work explores the possibility of combining 3D printing and topology optimization to produce lightweight transtibial prosthetic sockets to reduce the manufacturing time, costs and material waste. Specifically, a topology optimization algorithm based on Finite Element (FE) method has been employed to determine the optimal material distribution for the prosthetic socket in Polyamide PA12. A FE analysis has been carried out to validate the behaviour of the optimized shape. Finally, the new shape has been 3D printed using the fused deposition modelling technology. Furthermore, a cost analysis has been performed on the 3D printed part and traditional prosthetic socket. The approach followed in the present work showed a time reduction of up to 50% for the production of the final prosthesis and a cost reduction of up to 80% compared to the traditional manufacturing process. Moreover, the optimization of the material distribution allows for a reduction of material use (i.e. −38%). This procedure demonstrates the potential of the proposed approach for developing an efficient and sustainable alternative in the manufacturing of prosthetic sockets. © 2025 The Authors