This project was a first iteration into this concept of custom-function 3D printed prosthetic covers. This design combines the needs and requests from clients to make a product that is suited to the individual. I wanted something that would be able to enhance the look and features of a regular prosthetic
What is the Multi-Fictional Prosthetic?
The purpose of this project was to combine fashion and function. In this design I use the already established idea of a a customized prosthetic cover and combine personalized features. I wanted to create someone that would not only allow the wearer to express themselves visually and have functions that could assist them in their daily lives. The first idea was a simple pocket. This could allow for added storage that could be more organized that a pocket. The first thought was aimed toward mechanics who could use the space to store different bits, nuts, bolts, and other smaller objects that could be easily lost. Then I found a subject. Working with him I started to personalize the features that I would add to the cover. For him specifically I am adding a bottle openner, the before mentioned pocket (but for phones and an added flask for water), and LED lights that will not only be a great party trick but also allow for added visability when running or biking at night.
Along with the prosthetic cover I wanted to look into how I could transfer this design to a full printed prosthetic leg; as well as why we dont see more 3D printed legs. The main areas of my research for this would show what reasons this process wasn’t practiced more often, what designs for this had been tried and worked, and what processes were used in creating these prosthetics. I chose to explore this posibility in a research fashion because I knew that testing a fully functioning prosthetic on a real person would create a lot more complications as it would pertain to school liabilities.
When I first saw Mr. Summit’s work, I saw what truly capable of when it came to custom pros-thetics. The way he broke the mold of traditional styles with material and design inspired me to think outside the box when it came to creating a prosthetic cover. He was gracious enough to allow me to give him a call. In my conversation with him I learned how he found inspiration for his designs. He also shared with me how he found the ideal candidate for working on a project like this.
Integza is his YouTube handle, his real name is Joel. Joel is a mechanical engineer who I watched and inspired the basic design of my prosthetic cover. He created a 3D printed cover for another individual. I was inspired by his 3-piece design that he used to give depth and make a coherent design. Although my design is based off his I made my own changes in order to create a cover that would not require the removal of the prosthetic foot.
This was the first company I saw who made 3D printed prosthetic covers. The images I saw of people who were wearing their covers were what inspired me to want to attempt to make one of my own. I saw a newfound confidence arise in the subjects of images. To me it created this intersection between fashion and function that I had yet to see. Before seeing their work, I just knew prosthetics to be for bringing back a sense or normalcy and function. After I realized they could be beautiful.
This was another company that I noticed doing great work with prosthetic covers. One thing I liked about their design over Alleles is how smooth and fitting the outer shape is. They sought to really mimic the shape of a leg when designing the cover. I also like its seamless looking de-sign. It looks more elegant that the Alleles cover. This design inspired me to push how I can form the legs a little more. It made me want to push my design even more.
The Brief
What are the goals of this project?
By the end of this I want to have a functioning prosthetic cover that is 3D printed and has functions requested by the client. Overall look and design of the project will also be based on requests from the client.
Who’s going to use the project?
For this particular model Zac is. The overall concept of the cover is able to be used by anyone with a prosthet-ic leg.
Who makes the decisions?
The final decisions will be made by Zac the client. He will have the final say on he would like his cover to look like due to the fact that he is the one wearing it. This concept is fully client driven and will vary based off the client. It is also important to note that although the client has the final say the designer will be adding impute to sway the opinion to a design that is visually well designed.
What is the scope of the project?
This project in this format seems like something I may continue to work on. Creating more prosthetics for cli-ents in order to improve daily life. Past that I do want to extend this project to create a full functioning prosthetic rather than just a cover.
What’s the problem you’re trying to solve?
I want to create a product that takes the simple idea of a prosthetic cover and elevates it. I want the cover to become more than just another visually accessory but something that improves quality of life.
What is the design flow?
First, I present the client with questions. What features interest you? how would you like this to look? If they don’t have any ideas in mind (which is expected to be the case) i then present them with options and ideas from myself to see if they can become integrated into their life. For the outer visual aspect, I show them ex-amples of other prosthetic covers based off of a style they present me. I then try to combine their idea look with what I think would look cool based of their aesthetic.
After this point it is a back and forth between design and approval. I want to make sure the client is completely satisfied with the product so this process may take some back and forth.
After we have settled on a design I go to print, assemble, and paint.
This is Zac
He studied film at The Pennsylvania State University. In his free time he enjoyed hanging out with friends and participating in the Triathlon Club. He’s a fun easy going guy who likes to show off a little.
Design Notes
It all begins with an idea. Maybe you want to launch a business. Maybe you want to turn a hobby into something more. Or maybe you have a creative project to share with the world. Whatever it is, the way you tell your story online can make all the difference.
Don’t worry about sounding professional. Sound like you. There are over 1.5 billion websites out there, but your story is what’s going to separate this one from the rest. If you read the words back and don’t hear your own voice in your head, that’s a good sign you still have more work to do.
Be clear, be confident and don’t overthink it. The beauty of your story is that it’s going to continue to evolve and your site can evolve with it. Your goal should be to make it feel right for right now. Later will take care of itself. It always does.
The Research
One huge aspect of this project was the research. First, I had to figure out is making a 3D printed leg would be possible. Secondly, I still wanted to try and apply my cover designs and ideas to a fully functional 3D printed prosthetic, so I had to see what materials and processes would be best for that.
Was it Possible?
Most of the research pointed to no. Although this process is practiced with arms; legs seemed to be more complicated. They had to be load bearing which was problematic with normal PLA style printing. I did stumble across an article form ALL3DP which looked to be a new website dedicated to 3D printing. This showed various designs of 3D printed legs that seemed to work.
https://all3dp.com/2/3d-printed-prosthetic-leg-most-promising-projects/
What Materials?
As someone who loved to explore new materials in 3D printing this one excited me the most. In doing this research I found a helpful article that talked about different materials and how they worked well and didn’t. I used this article to base the strength of what would be possible and to evaluate what processes would be best. I also found another helpful article that talked about new materials in 3D printing. This opened me up to the possibility of using materials like Carbon Fiber filament, conductive filament, and flexible filament. all of which I thought could be helpful when it came to creating the most stable prosthetic leg.
https://www.prescouter.com/2017/07/3d-printed-prosthetics/
How Will I Print it?
In my research I notied that it seemed to be to be the process of printing may be slightly problematic. It seemed that there was the chance that it may not take very well to the load bearing and motion from walking. In a rabbit hole I went down I noticed a video from BBC that showed a company creating a prosthetic from a 3D Resin Printer. This loved that previous issue because the printing process creates a more stable bond between the layers. So I figured if I was going to produce a prosthetic then I would need a mixture of traditional 3D printing and 3D Resin Printing.