Modular distal plate for rapid manufacturing of a prosthetic limb socket

• US 6,358,453 B1
• Filed: 04/08/1999
• Issued: 03/19/2002
• Est. Priority Date: 04/09/1998
• Status: Expired due to Fees

• Current Assignee: Prosthetic Design Incorporated
• Original Assignee: Prosthetic Design Incorporated
• Inventors: Slemker, Tracy C., Schall, Scott R.
• Primary Examiner(s): SNOW, BRUCE EDWARD
• Application Number:
  US09/288,331
• Time in Patent Office: 1,076 Days
• Field of Search: 264/5, 264/274, 264/222, 264/308, 623/901, 623/33, 623/34
• US Class Current: 264/222
• CPC Class Codes: A61F 2/5044 Designing or manufacturing processes
• CPC Class Codes: A61F 2/80 Sockets, e.g. of suction type
• CPC Class Codes: A61F 2002/30331 made by longitudinally pushing a protrusion into a complementarily-shaped recess, e.g. held by friction fit
• CPC Class Codes: A61F 2002/30354 Cylindrically-shaped protrusion and recess, e.g. cylinder of circular basis
• CPC Class Codes: A61F 2002/30359 Pyramidally- or frustopyramidally-shaped protrusion and recess
• CPC Class Codes: A61F 2002/30387 Dovetail connection
• CPC Class Codes: A61F 2002/30492 using a locking pin
• CPC Class Codes: A61F 2002/505 using CAD-CAM techniques or NC-techniques
• CPC Class Codes: A61F 2220/0025 Connections or couplings between prosthetic parts, e.g. between modular parts; Connecting elements
• CPC Class Codes: A61F 2220/0033 made by longitudinally pushing a protrusion into a complementary-shaped recess, e.g. held by friction fit
• CPC Class Codes: B22F 10/18 by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 3/115 by spraying molten metal, i.e. spray sintering, spray casting
• CPC Class Codes: B29C 41/20 incorporating preformed parts or layers, e.g. moulding inserts or for coating articles
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29K 2105/20 Inserts
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G05B 19/00 Programme-control systems
• CPC Class Codes: G05B 2219/45168 : Bone prosthesis
• CPC Class Codes: Y02P 10/25 : Process efficiency
• CPC Class Codes: Y10S 623/901 : Method of manufacturing prosthetic device

Abstract

The present invention facilitates the use of the rapid manufacturing systems in the manufacture of prosthetic limb sockets by providing a substantially flat and strong distal attachment plate or base for the deposition of the fused-deposition-modeling materials thereon. The present invention also provides a method for fabricating a socket of a prosthetic limb which comprises the steps of: (a) providing a substantially flat distal attachment plate, where the attachment plate includes a coupling mechanism carried thereon for coupling a prosthetic upright assembly thereto; and (b) repeatedly depositing layers of solidifying material to the proximal surface of the attachment plate, controlled, at least in part, according to the dimensions of the patient'"'"'s residual limb, so as to form a socket for receiving the patient'"'"'s residual limb. The attachment plate may have a notch machined or formed into its proximal surface, about a periphery thereof, for receiving a first layer of the solidifying material and providing at least two bonding surfaces for the solidifying material.

Claims

1. A method for fabricating a socket component for a prosthetic limb comprising the steps of:

(a) providing an attachment plate, the attachment plate including coupling means carried thereon for coupling a prosthetic limb upright assembly thereto, and the attachment plate including a proximal surface; and

(b) repeatedly depositing layers of solidifying material to the proximal surface of the attachment plate so as to form a socket for receiving a patient'"'"'s residual limb.

2. The method of claim 1, wherein the attachment plate includes a notch extending into the proximal surface and which extends about an outer periphery of the attachment plate;

and step (b) includes a step of depositing at least one layer of the solidifying material into the notch;

whereby the notch provides at least two faces for the one layer of solidifying material to bond with.

3. The method of claim 1, wherein the attachment plate is substantially planar and the coupling means includes at least one bolt-receiving hole bored vertically through the attachment plate.

4. The method of claim 1, wherein step (b) includes a step of depositing at least one layer of the solidifying material onto the proximal surface of the attachment plate in a substantially helical, vertical pattern.

5. The method of claim 1, wherein the solidifying material includes a first material that solidifies as a substantially rigid solid and a second material that solidifies as a solid which is more flexible than the solid of the first material;

and step (b) includes a step of controlling the deposition of the first and second materials, separately or in combination, in portions of the socket depending upon endoskeletal or musculature characteristics of the patient'"'"'s residual limb.

6. The method of claim 5, wherein a greater proportion of the second material is deposited in portions of the socket providing lesser support for the patient'"'"'s residual limb.

7. The method of claim 6, wherein a greater proportion of the first material is deposited in portions of the socket providing greater support for the patient'"'"'s residual limb.

8. The method of claim 1, wherein step (b) includes the step of controlling the deposition of the layers of solidifying material according, at least in part, to dimensions of a patient'"'"'s residual limb.