Design and development of a novel 3D-printed non-metallic self-locking prosthetic arm for a forequarter amputation

Background: Upper limb, in particular forequarter amputations, require highly customised devices that are often expensive and underutilised. Objectives: The objective of this study was to design and develop a comfortable 3D-printed cosmetic forequarter prosthetic device, which was lightweight, cool to wear, had an elbow that could lock, matched the appearance of the contralateral arm and was completely free of metal for a specific user's needs. Study Design: Device design. Technique: An iterative user-centred design approach was used for digitising, designing and developing a functional 3D-printed prosthetic arm for an acquired forequarter amputation, while optimising the fit and function after each prototype. Results: The cost of the final arm was 20% less expensive than a traditionally-made forequarter prostheses in Singapore. The Quebec User Evaluation of Satisfaction with Assistive Technology (QUEST) 2.0 survey was administered, with results indicating that the 3D-printed arm was preferred due to its overall effectiveness, accurate size, ease of use and suspension. However, durability had a lower score, and the weight of the arm was 100 g heavier than the user's current prosthesis. The technique described resulted in a precise fitting and shaped forequarter prosthesis for the user. Using the user's feedback in the iterations of the design resulted in improved QUEST survey results indicating the device was effective, easy to use, perceived as lighter and more secure than the user's traditionally-made device. Conclusion: A fully customised cosmetic forequarter prosthesis was designed and developed using digital scanning, computer-aided design modelling and 3D printing for a specific user. These technologies enable new avenues for highly complex prosthetic design innovations.

Automated summary

This study aimed to design and develop a 3D-printed cosmetic forequarter prosthesis that is fully customized, lightweight, cool to wear, and matches the user's appearance needs. By using an iterative user-centered design approach, the final cost was 20% cheaper than traditional forequarter prostheses and received high user satisfaction.