10 page summary highlighting research and design process
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Workflow of design process
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Iterations of Feet
With force topology meshes
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Load cases of feet
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Split toe for lateral propulsion
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Fits with industry standard aligners
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Current prices of prosthetic legs cost between £3,000 to £50,000. For adults, a new prosthetic leg is needed every 2-5 years. Furthermore, lower limb amputees normally have several legs for different purposes. Amputees spend an average of £100,000 extra in their lifetime compared to non-amputees due to their limb loss and adaptations to their lifestyle.
Prosthetic feet are mass manufactured products, which are usually still expensive. Patients don’t usually get feet which are optimal for their biomechanics due to lack of analysis and budget constraints on clinics.
3D printing has been at the forefront of prototyping for many years now, but it has seldom been used in final production. For my final project, I explored opportunities where 3D printing could be used as an actual manufacturing solution. 3D printing is a solution that can lower the cost of prosthetic feet, whilst also tailoring each foot to the patient, leading to better walking mechanics and rehabilitation. This project explores a workflow that can be conducted to quickly adjust a foot framework for each patient to suit their individual needs.
Product design engineering has allowed me to apply my technical skills from my traditional mechanical engineering degree to solve problems through design. Moving forward, I am excited to continue developing my skills in design engineering and I’m actively seeking roles or research opportunities in mechanical design.