Research on Prosthetic limb Design Driven by New Manufacturing Processes

Abstract

Traditional prosthetic limb manufacturing has long relied on traditional processes such as subtractive manufacturing, which has inherent limitations such as low customization, high cost, and long production cycle. In recent years, new manufacturing processes such as additive manufacturing and composite material forming have provided disruptive solutions for personalized, lightweight and functional prosthetic design. This article aims to systematically study the comprehensive impact of new manufacturing processes on the functionality, economy and user experience of prosthetic limbs. Through literature review, the evolution of technology is reviewed. Through case analysis, advanced prosthetic design cases are studied. A comprehensive performance index evaluation system and a total cost of ownership (TCO) model are constructed to quantitatively compare the differences between traditional and new manufacturing processes. The research results show that the design based on 3D printing and composite materials can significantly reduce the weight of prosthetic limbs, enhance structural strength, shorten the customization cycle and lower the cost per piece. In addition, the user experience has also significantly improved in terms of aesthetics, comfort and psychological acceptance. This paper ultimately proposes an optimization framework for prosthetic limbs that integrates materials, design and manufacturing processes, providing a theoretical basis and practical guidance for the future research and development of high-performance and highly accessible prosthetic limbs.