Automated Design and Rapid Manufacturing of Low-Cost Customized Upper Limb Prostheses

The paper presents results of studies on an innovative approach to mass customization of prostheses, namely automated design and rapid manufacturing (3D printing), on the basis of 3D scanning of upper limb of a given patient. Two different products are presented – a simple mechanical prosthesis and a cosmetic prosthesis. In both cases, intelligent CAD models, with adaptive geometry – changing automatically to the data from 3D scanning – were prepared. The digital models were built and tested using data of real patients. A special algorithm of 3D scanning data processing was prepared and implemented, as well as a set of algorithms of automated data processing for 3D printing processes. The test models were manufactured using low-cost 3D printing technology. The verification was successful – possibility of preparing customized prostheses was reached, using automated design.