UNIBODY ENDOSKELETAL TRANSTIBIAL PROSTHETIC DEVICES AND DIGITAL FABRICATION WORKFLOW

1 . A unibody transtibial prosthetic device, comprising:

a socket configured to attach to a residual limb;

a pylon extending from the socket, the pylon being a unitary polymer structure of interconnected elongated supports having open spaces therebetween; and

a foot-ankle complex, the foot-ankle complex being a unitary polymer extending from the pylon, the foot and ankle unitary structure being shaped to provide multi-axial dynamic flex.

2 . The unibody transtibial prosthetic device of claim 1 , wherein the socket, pylon and foot-ankle complex are a unitary single piece.

3 . The unibody transtibial prosthetic device of claim 1 , wherein the unitary single piece comprises a single polymer.

4 . The unibody transtibial prosthetic device of claim 1 , wherein the unitary single piece comprises multiple materials with different stiffnesses.

5 . The unibody transtibial prosthetic device of claim 1 , wherein the pylon is shaped and dimensioned to be within extended external boundaries of the residual limb.

6 . The unibody transtibial prosthetic device of claim 1 , wherein the interconnected elongated supports define a central open cavity and curve around the open cavity.

7 . The unibody transtibial prosthetic device of claim 6 , wherein the interconnected elongated supports and open spaces therebetween model a mirrored boundary of a contralateral transtibial leg portion of a patient.

8 . The unibody transtibial prosthetic device of claim 6 , wherein the central open cavity has a decreasing diameter from the socket to the foot-ankle complex.

9 . The unibody transtibial prosthetic device of claim 1 , wherein the interconnected elongated supports and open spaces define an endoskeleton shape complementary model of a contralateral transtibial leg portion of a patient.

10 . The unibody transtibial prosthetic device of claim 1 , wherein the pylon is formed of thermoplastic.

11 . The unibody transtibial prosthetic device of claim 1 , wherein the foot-ankle complex comprises a split ankle structure.

12 . The unibody transtibial prosthetic device of claim 11 , wherein the split ankle structure comprises an s-shaped posterior portion and s-shaped anterior portion separated from each other by a gap extending from terminal portion of the s-shaped anterior portion to a sole portion.

13 . The unibody transtibial prosthetic device of claim 12 , wherein the s-shaped posterior portion is solid and thicker than the s-shaped anterior portion.

14 . The unibody transtibial prosthetic device of claim 13 , wherein an upper portion of the s-shaped posterior portion is unitary with lowest portion of the pylon.

15 . The unibody transtibial prosthetic device of claim 13 , wherein the s-shaped anterior portion comprises one or more pass-through openings.

16 . The unibody transtibial prosthetic device of claim 11 , wherein the sole portion comprises a split toe and a split heel.

17 . The unibody transtibial prosthetic device of claim 1 , wherein the foot-ankle complex comprises a central strip of stiffer material surrounded by more flexible material.

18 . The unibody transtibial prosthetic device of claim 1 , wherein an outer surface of the entire transtibial prosthetic device is flexible material and includes a core of stiffer material.

19 . A patient specific workflow method for producing a unibody transtibial prosthetic device, the workflow comprising:

acquiring patient data via imaging and/or scanning;

constructing a 3D model from the patient data;

translating the 3D model to 3D printable design of a unibody transtibial prosthesis;

3D printing the unibody transtibial prosthesis.

20 . The method of claim 19 , wherein the acquiring patient data comprises imaging a contralateral limb and residual limb..