Digital to definitive orthotic and prosthetic device manufacturing system and method
Systems and methods for creating custom-fit prosthetic devices, orthotic devices, and related medical devices via three-dimensional printing (3D printing) or additive manufacturing techniques are described. Through the described systems and methods, a residual limb or other body part of a patient is scanned and analyzed to determine measurements and characteristics of the residual limb. The measurements and characteristics of the residual limb are used to design a customized device for the residual limb. The customized device uses multiple different materials. For example, the customized device may use a first material for a frame and a second material for a liner, wherein the first material is more rigid than the second material. The customized device is fabricated using a three-dimensional printer that is capable of printing and bonding multiple different materials at the same time.
1. A prosthetic device comprising:
a socket defining a cavity configured to receive a residual limb of a user, wherein the socket is formed by a three-dimensional printing process;
a pylon coupled to the distal end of the socket by a threaded fastener; and
a connection insert within the socket, the connection insert comprising an internally threaded fastener aligned with a through hole in the socket, wherein the internally threaded fastener is structured to receive the threaded fastener thereby securing the pylon to the socket;
wherein the socket formed by the three-dimensional printing process extends along an entirety of a top surface of the connection insert;
wherein at least one of a vacuum line or a wire passes from an exterior of the socket, through a central opening of the connection insert, and into the cavity defined by the socket.
2. The device of claim 1 , wherein the connection insert is comprised of metal, and wherein the socket is comprised of three-dimensionally printed plastic.
3. The device of claim 1 , wherein the connection insert is not disc-shaped.
4. A prosthetic device comprising:
a socket defining a cavity configured to receive a residual limb of a user, wherein the socket is formed by a three-dimensional printing process;
a pylon coupled to the distal end of the socket by a threaded fastener; and
a connection insert within the socket, the connection insert comprising an internally threaded fastener aligned with a through hole in the socket, wherein the internally threaded fastener is structured to receive the threaded fastener thereby securing the pylon to the socket;
wherein the socket formed by the three-dimensional printing process extends along an entirety of a top surface of the connection insert;
wherein the connection insert is not disc-shaped;
wherein the internally threaded fastener is a first internally threaded fastener, wherein the connection insert further comprises a second internally threaded fastener, a third internally threaded fastener, and a fourth internally threaded fastener.
5. The device of claim 4 , wherein each of the first, second, third, and fourth internally threaded fasteners define a circular opening having a center point, wherein the first, second, third, and fourth internally threaded fasteners are positioned such that the four center points define the vertices of a square.
6. The device of claim 4 , wherein the connection insert has an overall X-shape.
7. The device of claim 4 , wherein the connection insert has an overall U-shape.
8. A prosthetic device comprising:
a socket defining a cavity configured to receive a residual limb of a user, wherein the socket is formed by a three-dimensional printing process;
a pylon coupled to the distal end of the socket by a threaded fastener; and
a connection insert provided within the socket, the connection insert comprising a connection insert body and a plurality of internally threaded fasteners coupled to the connection insert body, wherein the connection insert body is configured to receive the threaded fastener thereby coupling the pylon to the socket;
wherein the socket formed by the three-dimensional printing process extends along an entirety of a top surface of the connection insert;
wherein the connection insert has an overall X-shape.
9. The prosthetic device of claim 8 , wherein the connection insert is not disc-shaped.
10. A prosthetic device comprising:
a socket defining a cavity configured to receive a residual limb of a user, wherein the socket is formed by a three-dimensional printing process;
a pylon coupled to the distal end of the socket by a threaded fastener; and
a connection insert provided within the socket, the connection insert comprising a connection insert body and a plurality of internally threaded fasteners coupled to the connection insert body, wherein the connection insert body is configured to receive the threaded fastener thereby coupling the pylon to the socket;
wherein the socket formed by the three-dimensional printing process extends along an entirety of a top surface of the connection insert; and
wherein the plurality of internally threaded fasteners comprise:
a first internally threaded fastener coupled to the connection insert body;
a second internally threaded fastener coupled to the connection insert body;
a third internally threaded fastener coupled to the connection insert body; and
a fourth internally threaded fastener coupled to the connection insert body.
11. The prosthetic device of claim 10 , wherein each of the first, second, third, and fourth internally threaded fasteners define a circular opening having a center point, wherein the first, second, third, and fourth internally threaded fasteners are positioned such that the four center points define the vertices of a square.