Integration of 3D Printing Technology into the Process of Manufacturing and Optimization of the Transfemoral Prosthesis

Marko Karačić; Amila Dedić; Remzo Dedić

doi:https://doi.org/10.47960/3029-3200.2025.1.2.1

Preliminary Communication

DOI: https://doi.org/10.47960/3029-3200.2025.1.2.1

Marko Karačić , Amila Dedić and Remzo Dedić*

	marko.karacic@fsre.sum.ba
	amila.dedic@unmo.ba
*CA	remzo.dedic@fsre.sum.ba

Full text:

Vol. 1 No. 2 Article 6

This article belongs to Vol. 1 No. 2, 2025

M. Karačić, A. Dedić, and R. Dedić, “Integration of 3D Printing Technology into the Process of Manufacturing and Optimization of the Transfemoral Prosthesis,” International Journal of Innovative Solutions in Engineering, vol. 1, no. 2, pp. 1–11, Jul. 2025, doi: 10.47960/3029-3200.2025.1.2.1.

pages 1-11

Download a citation file:

Vol. 1 No. 2 Article 6 Download

Preview and download a citation file in BibTex format that can be imported by citation management software, including Mendeley, EndNote, ProCite, RefWorks, and Reference Manager.

This article is archived in Zenodo

Abstract

This paper describes the process of creating a new type 3D model of an above-knee prosthesis and its subsequent 3D printing using modern technology. The introduction provides a brief history of prosthetics, kinematics of new prosthesis mechanism, highlighting the advantages of contemporary solutions over earlier models. Following this, the components of the above-knee prosthesis are described in detail, along with the CAD technology used to create the 3D model, as well as an analysis of the issues with previous prosthetic prototypes and the necessary design modifications. A 3D model of the hydraulic cylinder was developed using SolidWorks, after which the remaining parts of the prosthesis were designed with the required adjustments. A static analysis was performed to verify that the prosthesis could support a weight of 120 kilograms. The paper also discusses additive manufacturing and the preparation for 3D printing of the parts. Finally, after 3D printing, the parts were assembled into the final above-knee prosthesis structure.

Keywords

3D Printing, Above-Knee Prosthesis, Hydraulic Cylinders

ijise ID

6

URI

https://ijise.ba/article/6/

Publication Date

Jul. 17, 2025

References

J. Edelstein and A. Moroz, Lower-Limb Prosthetics and Orthotics: Clinical Concepts. Thorofare: SLACK Incorporated, 2010.
F. R. T. Nelson and C. T. Blauvelt, A manual of orthopaedic terminology, 8th edition. Philadelphia, PA: Elsevier/Saunders, 2015.
H. Mihajlo, “Contribution to the analysis of hydraulic components for upper leg prostheses”, University of Mostar, Faculty of Mechanical Engineering, Mostar, 2001.
A. Žiga, “Foot design of above-the-knee prosthesis with built-in hydraulic actuators in the ankle and knee”, University of Zenica, Faculty of Mechanical Engineering, Zenica, 2006.
M. Rupar, “Contribution to the research of above-knee prosthesis with active hydraulically driven knee and ankle joints and prosthetic foot with passive joint bending in the front part”, University of Mostar, Faculty of Mechanical Engineering and Computing, Mostar, 2017.
M. Arazpour, Ed., Prosthetics and Orthotics. Erscheinungsort nicht ermittelbar: IntechOpen, 2021.
A. J. Thurston, “Paré and prosthetics: the early history of artificial limbs”, ANZ Journal of Surgery, vol. 77, no. 12, pp. 1114–1119, Dec. 2007, doi: https://doi.org/10.1111/j.1445-2197.2007.04330.x.
J. P. D. Kaushik Kumar, “A Brief History of Prosthetics and Orthotics of the Lower Body and Their Types”, Design, Development, and Optimization of Bio-Mechatronic Engineering Products, IGI Global, 2019.
J. Gardiner, A. Z. Bari, D. Howard, and L. Kenney, “Transtibial amputee gait efficiency: Energy storage and return versus solid ankle cushioned heel prosthetic feet”, J Rehabil Res Dev, vol. 53, no. 6, pp. 1133–1138, 2016, doi: https://doi.org/10.1682/JRRD.2015.04.0066.
K. B. Fite, “Overview of the Components Used in Active and Passive Lower-Limb Prosthetic Devices”, in Full Stride, V. Tepe and C. M. Peterson, Eds., New York, NY: Springer New York, 2017, pp. 55–74. doi: https://doi.org/10.1007/978-1-4939-7247-0_4.
M. Husnjak, “Teorija mehanizama”, p. 427, 1996, Accessed: Apr. 09, 2025. [Online]. Available: https://www.croris.hr/crosbi/publikacija/prilog-knjiga/23816.
Z. Jelačić, R. Dedić, and H. Dindo, “Chapter 5 – Prosthetic design and prototype development”, in Active Above-Knee Prosthesis, Z. Jelačić, R. Dedić, and H. Dindo, Eds., Academic Press, 2020, pp. 155–199. doi: https://doi.org/10.1016/B978-0-12-818683-1.00005-6.
R. Dedić, Roboti. Mostar: Sveučilište u Mostaru, 2008.
“Understanding Hydraulic Cylinders: The Power Behind Your Machinery – SNS Pneumatic”. Accessed: Apr. 10, 2025. [Online]. Available: https://snspneumatic.com/understanding-hydraulic-cylinders-the-power-behind-your-machinery/
M. Rupar, Z. Jelačić, R. Dedić, and A. Vučina, “Power and Control System of Knee and Ankle Powered Above-Knee Prosthesis”, Sarajevo: Academy of Sciences and Arts of Bosnia and Herzegovina, Jun. 2018.
H. Dindo, Z. Husnic, R. Dedic, and A. Vucina, “Smart LEG Control System Optimization”, in Advanced Technologies, Systems, and Applications II, M. Hadžikadić and S. Avdaković, Eds., Cham: Springer International Publishing, 2018, pp. 1189–1199. doi: https://doi.org/10.1007/978-3-319-71321-2_102.
R. Gehlhar, “Model-Based Lower-Limb Powered Prosthesis Control: Developing and Realizing Nonlinear Subsystem Control Methods for Generalizable Prosthesis Control”, phd, California Institute of Technology, 2023. doi: https://doi.org/10.7907/6724-6e14.
S. Chemello and H. Ansaripour, “Finite element analysis of socket optimization in accordance with the deformation of external surface of the stump”, Dec. 2018, Accessed: Apr. 10, 2025. [Online]. Available: https://www.politesi.polimi.it/handle/10589/145138
I. Gibson, D. W. Rosen, and B. Stucker, Additive manufacturing technologies: 3D printing, rapid prototyping and direct digital manufacturing, 2nd edition. New York London: Springer, 2015.
C. Zhang et al., “Additive manufacturing of functionally graded materials: A review”, Materials Science and Engineering: A, vol. 764, p. 138209, Sep. 2019, doi: https://doi.org/10.1016/j.msea.2019.138209.
M.Z. Cordero, R Dedic, Z Jelacic, R Toshev – Optimizing Mechanical Design for an Additively Manufactured Prosthetic Leg, Procedia Computer Science, 2024.
N. Rašović, “Recommended layer thickness to the powder-based additive manufacturing using multi-attribute decision support”, International Journal of Computer Integrated Manufacturing, vol. 34, no. 5, pp. 455–469, May 2021, doi: https://doi.org/10.1080/0951192X.2021.1891574.
I. Krešić, J. Kaljun, and N. Rašović, “Controlling the Mechanical Response of Stochastic Lattice Structures Utilizing a Design Model Based on Predefined Topologic and Geometric Routines”, Applied Sciences, vol. 14, no. 14, p. 6048, Jul. 2024, doi: https://doi.org/10.3390/app14146048.