Final Technical Presentation For Manufacturing A Prosthetic Socket

Presented For: Dave Lewis, Darlene Webb, and Greg King

BCIT Mechanical Engineering Department

Presented By: Kevin Yu

Presented Date: May 7th 2015

Agenda Introduction Sponsors Manufacturing Processes Schedule Budget Problems Outcome Questions

Introduction

A Prosthetic Socket

Fig 1. Prosthetic socket sample Fig 2. Prosthetic socket sample

Background

What is a prosthetic socket?

Fig 3. Prosthetic Limbhttp://www.mccleveop.com/prosthetics/below-knee-amputation/

Purpose To create a Prosthetic socket in a short amount of time Current method:

Plaster mold Have to sculpt mold

Method Used: Use 3D scanning and CAD software 3D Printing

Fig 4. Plaster Mold http://biomedical.materialise.com/cases/step-forward-below-knee-prosthesis-socket-design

3D Technology Potential

Scanned data can be stored for future usage

Scanned geometry is more accurate

Virtual testing

Sponsors

Caroline Soo, B.Sc., M.Sc., DipT P&O Research Coordinator at BCIT Clinical Prosthetics and Orthotics, School of Health

Sciences

Johanne Mattie, MASc BCIT’s MAKE+ Technology Centre

Manufacturing Process – Project Breakdown

Designing • 3D scanning• 3D modelling

Manufacturing• 3D Printing

Manufacturing Process – Step By Step Process

3D Scanning

CAD Modelling

3D Printing

3D Scanning

VX Elements

1 Hour scan time

CAD Model

Fig 6. Right Side of Point Cloud Model Fig 7. Right Side of View 3D Model

CAD Model

Fig 9. Right Side of Point Cloud ModelFig 8. SolidWorks Design Tree

3D Printing

ZPrinter® 310 Plus

Fortus 400mc

Fig 10. ZPrinter® 310 Plus Fig 11. Fortus 400mc

3D Printing

Binder: ZB60Powder: ZP131

9 Different Thermoplastics - Polycarbonate (PC)

Fig 12. Prototype Socket Fig 13. Final Prosthetic Socket

Problems

Scaling

Major modifications causes error

Proposed BudgetBillable $/hr Hours Cost

Designing 20 120 $2,040

Student Labor 30 48 $960

3D Scanner 15 6 $90

  $/Setup # of Setup

3D Printer 45 3 $135

  $/gram Weight (gram)  

3D Printer Material 0.20 544 $108.5

Total Cost$3133.5

0

Final BudgetBillable $/hr Hours Cost

Designing 20 180 $3600

Student Labor 20 18 $3603D Scanner 15 1 $15

  $/Setup # of Setup 3D Printer 45 3 $135

  $/gram Weight (gram)  

3D Printer Material 0.20 544 $109

Total Cost $4219

Difference +1085.50

Cost for ClientBillable $/hr Hours Cost

Designing 20 3 $60

Number of socket made Price

Prosthetic Socket 1 ~$300-$400 $350

Total Cost $410

Proposed Schedule

Design

Proposal

3D Printing

Spring Break

Modifications

3D Printing

Term Project Report

Oral Presentation Practice

21-Ja

n

31-Ja

n

10-F

eb

20-F

eb

2-M

ar

12-M

ar

22-M

ar

1-Apr

11-A

pr

21-A

pr

1-M

ay

11-M

ay

Final Schedule

Design

Proposal

Spring Break

Modifications

3D Printing

Term Project Report

Oral Presentation Practice

21-Ja

n

31-Ja

n

10-F

eb

20-F

eb

2-M

ar

12-M

ar

22-M

ar

1-Apr

11-A

pr

21-A

pr

1-M

ay

11-M

ay

Future Work

Add modifications

Perform Finite Element Analysis (FEA) on socket design

Find a way to import cloud point without SolidWorks down scaling the model

Outcome

3D scanned a “residual limb”

Created a 3D prosthetic socket

3D printed socket model

Questions

Fig 14. Question Mark http://images.clipartpanda.com/purple-question-mark-clip-art-question-mark.jpg