Topologically Optimized Anthropomorphic Prosthetic Limb: Finite Element Analysis and Mechanical Evaluation Using Plantogram-Derived Foot Pressure Data
The development of prosthetic limbs has benefited individuals who suffered amputations due to accidents or medical conditions. During the development of conventional prosthetics, several challenges have been observed regarding the functional limitations, the restricted degrees of freedom compared to...
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MDPI AG
2025-04-01
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| author | Ioannis Filippos Kyriakidis Nikolaos Kladovasilakis Marios Gavriilopoulos Dimitrios Tzetzis Eleftheria Maria Pechlivani Konstantinos Tsongas |
| author_facet | Ioannis Filippos Kyriakidis Nikolaos Kladovasilakis Marios Gavriilopoulos Dimitrios Tzetzis Eleftheria Maria Pechlivani Konstantinos Tsongas |
| author_sort | Ioannis Filippos Kyriakidis |
| collection | DOAJ |
| description | The development of prosthetic limbs has benefited individuals who suffered amputations due to accidents or medical conditions. During the development of conventional prosthetics, several challenges have been observed regarding the functional limitations, the restricted degrees of freedom compared to an actual human limb, and the biocompatibility issues between the surface of the prosthetic limb and the human tissue or skin. These issues could result in mobility impairments due to failed mimicry of the actual stress distribution, causing discomfort, chronic pain, and tissue damage or possible infections. Especially in cases where underlying conditions exist, such as diabetes, possible trauma, or vascular disease, a failed adaptation of the prosthetic limb could lead to complete abandonment of the prosthetic part. To address these challenges, the insertion of topologically optimized parts with a biomimetic approach has allowed the optimization of the mimicry of the complex functionality behavior of the natural body parts, allowing the development of lightweight efficient anthropomorphic structures. This approach results in unified stress distribution, minimizing the practical limitations while also adding an aesthetic that aids in reducing any possible symptoms related to social anxiety and impaired social functioning. In this paper, the development of a novel anthropomorphic designed prosthetic foot with a novel Thermoplastic Polyurethane-based composite (TPU-Ground Tire Rubber 10 wt.%) was studied. The final designs contain advanced sustainable polymeric materials, gyroid lattice geometries, and Finite Element Analysis (FEA) for performance optimization. Initially, a static evaluation was conducted to replicate the phenomena at the standing process of a conventional replicated above-knee prosthetic. Furthermore, dynamic testing was conducted to assess the mechanical responses to high-intensity exercises (e.g., sprinting, jumping). The evaluation of the dynamic mechanical response of the prosthetic limb was compared to actual plantogram-derived foot pressure data during static phases (standing, light walking) and dynamic phenomena (sprinting, jumping) to address the optimal geometry and density, ensuring maximum compatibility. This innovative approach allows the development of tailored prosthetic limbs with optimal replication of the human motion patterns, resulting in improved patient outcomes and higher success rates. The proposed design presented hysteretic damping factor and energy absorption efficiency adequate for load handling of intense exercises (0.18 loss factor, 57% energy absorption efficiency) meaning that it is suitable for further research and possible upcycling. |
| format | Article |
| id | doaj-art-aeef92a0081f4c64b2aba2823d054e1e |
| institution | DOAJ |
| issn | 2313-7673 |
| language | English |
| publishDate | 2025-04-01 |
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| series | Biomimetics |
| spelling | doaj-art-aeef92a0081f4c64b2aba2823d054e1e2025-08-20T03:14:38ZengMDPI AGBiomimetics2313-76732025-04-0110526110.3390/biomimetics10050261Topologically Optimized Anthropomorphic Prosthetic Limb: Finite Element Analysis and Mechanical Evaluation Using Plantogram-Derived Foot Pressure DataIoannis Filippos Kyriakidis0Nikolaos Kladovasilakis1Marios Gavriilopoulos2Dimitrios Tzetzis3Eleftheria Maria Pechlivani4Konstantinos Tsongas5Advanced Materials and Manufacturing Technologies Laboratory, Department of Industrial Engineering and Management, School of Engineering, International Hellenic University, 57001 Thessaloniki, GreeceInformation Technologies Institute/Centre for Research and Technology Hellas, 57001 Thessaloniki, GreeceAdvanced Materials and Manufacturing Technologies Laboratory, Department of Industrial Engineering and Management, School of Engineering, International Hellenic University, 57001 Thessaloniki, GreeceDigital Manufacturing and Materials Characterization Laboratory, School of Science and Technology, International Hellenic University, 57001 Thermi, GreeceInformation Technologies Institute/Centre for Research and Technology Hellas, 57001 Thessaloniki, GreeceAdvanced Materials and Manufacturing Technologies Laboratory, Department of Industrial Engineering and Management, School of Engineering, International Hellenic University, 57001 Thessaloniki, GreeceThe development of prosthetic limbs has benefited individuals who suffered amputations due to accidents or medical conditions. During the development of conventional prosthetics, several challenges have been observed regarding the functional limitations, the restricted degrees of freedom compared to an actual human limb, and the biocompatibility issues between the surface of the prosthetic limb and the human tissue or skin. These issues could result in mobility impairments due to failed mimicry of the actual stress distribution, causing discomfort, chronic pain, and tissue damage or possible infections. Especially in cases where underlying conditions exist, such as diabetes, possible trauma, or vascular disease, a failed adaptation of the prosthetic limb could lead to complete abandonment of the prosthetic part. To address these challenges, the insertion of topologically optimized parts with a biomimetic approach has allowed the optimization of the mimicry of the complex functionality behavior of the natural body parts, allowing the development of lightweight efficient anthropomorphic structures. This approach results in unified stress distribution, minimizing the practical limitations while also adding an aesthetic that aids in reducing any possible symptoms related to social anxiety and impaired social functioning. In this paper, the development of a novel anthropomorphic designed prosthetic foot with a novel Thermoplastic Polyurethane-based composite (TPU-Ground Tire Rubber 10 wt.%) was studied. The final designs contain advanced sustainable polymeric materials, gyroid lattice geometries, and Finite Element Analysis (FEA) for performance optimization. Initially, a static evaluation was conducted to replicate the phenomena at the standing process of a conventional replicated above-knee prosthetic. Furthermore, dynamic testing was conducted to assess the mechanical responses to high-intensity exercises (e.g., sprinting, jumping). The evaluation of the dynamic mechanical response of the prosthetic limb was compared to actual plantogram-derived foot pressure data during static phases (standing, light walking) and dynamic phenomena (sprinting, jumping) to address the optimal geometry and density, ensuring maximum compatibility. This innovative approach allows the development of tailored prosthetic limbs with optimal replication of the human motion patterns, resulting in improved patient outcomes and higher success rates. The proposed design presented hysteretic damping factor and energy absorption efficiency adequate for load handling of intense exercises (0.18 loss factor, 57% energy absorption efficiency) meaning that it is suitable for further research and possible upcycling.https://www.mdpi.com/2313-7673/10/5/261orthopedic biomechanicsanthropomorphic designbioinspired topology optimizationmechanical propertiesTPUground tire rubber composites |
| spellingShingle | Ioannis Filippos Kyriakidis Nikolaos Kladovasilakis Marios Gavriilopoulos Dimitrios Tzetzis Eleftheria Maria Pechlivani Konstantinos Tsongas Topologically Optimized Anthropomorphic Prosthetic Limb: Finite Element Analysis and Mechanical Evaluation Using Plantogram-Derived Foot Pressure Data Biomimetics orthopedic biomechanics anthropomorphic design bioinspired topology optimization mechanical properties TPU ground tire rubber composites |
| title | Topologically Optimized Anthropomorphic Prosthetic Limb: Finite Element Analysis and Mechanical Evaluation Using Plantogram-Derived Foot Pressure Data |
| title_full | Topologically Optimized Anthropomorphic Prosthetic Limb: Finite Element Analysis and Mechanical Evaluation Using Plantogram-Derived Foot Pressure Data |
| title_fullStr | Topologically Optimized Anthropomorphic Prosthetic Limb: Finite Element Analysis and Mechanical Evaluation Using Plantogram-Derived Foot Pressure Data |
| title_full_unstemmed | Topologically Optimized Anthropomorphic Prosthetic Limb: Finite Element Analysis and Mechanical Evaluation Using Plantogram-Derived Foot Pressure Data |
| title_short | Topologically Optimized Anthropomorphic Prosthetic Limb: Finite Element Analysis and Mechanical Evaluation Using Plantogram-Derived Foot Pressure Data |
| title_sort | topologically optimized anthropomorphic prosthetic limb finite element analysis and mechanical evaluation using plantogram derived foot pressure data |
| topic | orthopedic biomechanics anthropomorphic design bioinspired topology optimization mechanical properties TPU ground tire rubber composites |
| url | https://www.mdpi.com/2313-7673/10/5/261 |
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