Design and Additive Manufacturing of a Lattice-Based, Ultra-Light Forearm Prosthesis

The development of next-generation upper limb prostheses demands a patient-centered approach that prioritizes comfort, functionality, and anatomical integration. This study presents the design, numerical simulation, and additive manufacturing of a lattice-based, ultra-light forearm prosthetic socket, developed within the Calliope project, a collaboration between Scuola Superiore Sant’Anna, the University of Pisa, and the University of Trento. The prosthesis integrates field-driven design (FDD) and finite element method (FEM) simulations to optimize structural performance while ensuring patient-specific adaptability. A biomechanically informed lattice structure was designed to minimize weight while maintaining mechanical strength, improving ventilation, and enhancing patient comfort. An elasto-plastic homogenization-based approach was employed to characterize the effective mechanical properties of the printed lattice. The socket geometry was customized using 3D scanning of the patient’s residual limb, enabling a highly tailored fit. The final prototype was fabricated using Multi Jet Fusion (MJF) technology with PA12, ensuring durability and manufacturability. Preliminary evaluations indicate that the developed prosthesis significantly improves comfort, aeration, and weight distribution, addressing key limitations of conventional sockets. This study demonstrates the potential of additive manufacturing in personalized medical device design, paving the way for next-generation prosthetic solutions.