3D printed prosthetic uses embedded pressure-mapping sensors

Researchers at Simon Fraser University (SFU) have developed a 3D printed prosthetic limb socket that uses embedded pressure sensors and artificial intelligence to generate custom socket designs, based on individual patient biomechanics.

The system centers on a silicone liner embedded with miniature pressure sensors that the patient wears beneath the socket. The liner continuously maps the distribution of forces across the residual limb during activities such as standing, walking, and leaning, and this produces a biomechanical profile that feeds into AI algorithms to generate a patient-specific socket design.

“For the first time, this 3D printing technology is capturing unique pressure and force distribution data from a patient, and using that data to design a custom prosthetic device and fabricate a much lighter, more breathable and pressure-responsive socket,” said Woo Soo Kim, Lead Professor of the Additive Manufacturing Lab at Simon Fraser University and corresponding author of the study published in Biosensors and Bioelectronics.

Lattice structures replace solid infill for superior energy absorption

The SFU team applied a lattice structure modeled on the Gyroid pattern — a continuous three-dimensional network geometry — to the socket’s construction, rather than a conventional solid-infill fabrication. Inspiration came from the structural principles found in honeycombs and trabecular bone, which offer more “spongey” structures.

The findings were significant. Testing showed that the lattice-based sockets absorbed energy at significantly higher rates than traditional designs.

When standing, energy absorption increased by 1,600%, while walking conditions produced a 1,290% increase in energy dissipation. Potential benefits for users could include reduced pressure ulcers, pain, and musculoskeletal complications associated with conventional prosthetic use.

The design also improved airflow through the socket and reduced overall weight, which combats common issues faced by prosthetic users, such as skin irritation and fatigue during extended wear.

Clinical partnership and accessibility goals

The project was developed in collaboration with Hodgson Group Orthotics and Prosthetics, whose prosthetists provided clinical validation and expertise on fit, load distribution, and long-term skin health outcomes.

Loren Schubert, prosthetist at Hodgson Group, explained that involvement in the development and evaluation process threw a sharp focus on how “data-driven design can meaningfully improve prosthetic fit, comfort, and long-term skin health — areas that have challenged our profession for decades.”

Cost reduction and manufacturing scalability were both central research objectives, with the aim of making the technology available through local prosthetic providers.

“We want to help local prosthetic companies better serve their clients, and make sure more comfortable, personalized prostheses are affordable and accessible to everyone who needs them,” added Kim.