Application of generative design and additive manufacturing in the development of a transtibial prosthesis prototype to reduce manufacturing costs

Abstract

Access to transtibial prostheses in Peru is limited due to high manufacturing costs and long delivery times associated with traditional fabrication methods. This research proposes the use of generative design and additive manufacturing as a technological alternative to significantly reduce these constraints. First, fundamental design criteria were defined based on ISO 22675 and ISO 10328 standards, establishing structural resistance requirements (1273 N and 50 N·m) for users weighing less than 100 kg, as well as morphological parameters representative of the average Peruvian population. Subsequently, a base model was developed in Fusion 360, applying geometric constraints, loading conditions, and material selection (PLA), to generate multiple optimized proposals through generative design. The selected model was manufactured using 3D printing and subjected to laboratory compression testing, evaluating mass, printing time, and maximum supported load. Results demonstrate that the prototype meets the established structural requirements while drastically reducing manufacturing costs, estimated at approximately 48 Peruvian soles, compared to local commercial ranges between 2,500 and 5,000 soles. Additionally, manufacturing time was reduced to approximately 28 hours. It is concluded that integrating generative design and 3D printing represents a viable, cost-effective, and technically suitable alternative to improve access to transtibial prostheses in resource-limited settings