3D-Printed Volume Adjustable Socket for Above-Knee Prostheses
Federico Donadel, Ahmed Zohaib Zaidi, Arianna Menciassi, Linda Paternò
Abstract
Traditional prosthetic sockets are rigid, passive structures that cannot accommodate daily residual limb volume fluctuations and are produced through labor-intensive processes involving environmentally and occupationally hazardous materials. This work presents a 3D-printed, volume-adjustable transfemoral socket integrating a motorized cable-driven mechanism and pressure monitoring. The design features a dual layer, concentric structure that enables uniform circumferential modulation via a BOA system, operable manually or through a DC motor. Four resistive sensors, embedded in a prosthetic liner with a magnetic suspension, provide interface pressure feedback for closed-loop control. The socket is fabricated using 3D-printed glass-filled PA12 and carbon-fiber-reinforced PEEK to optimize strength, weight, and reduce material waste by means of a more sustainable production process. Experimental validation showed that the system maintains interface pressure within the target range (70 ± 2 kPa), limits relative vertical displacement down to <6 mm under realistic tension load, and withstands static and dynamic forces up to 900 N without structural failure. This solution combines adaptive design with sustainable digital manufacturing, offering a robust foundation for next-generation wearable physical interfaces that enhance comfort and stability.
BibTeX
@inproceedings{ral2026_3dprintedvolumea,
title = {3D-Printed Volume Adjustable Socket for Above-Knee Prostheses},
author = {Federico Donadel and Ahmed Zohaib Zaidi and Arianna Menciassi and Linda Paternò},
booktitle = {RA-L 2026},
year = {2026}
}