Additive manufacturing produced prosthetic foot

Abstract

Various systems, apparatuses, and methods for producing a prosthetic foot by an additive manufacturing process are disclosed.

1 . A prosthetic foot comprising:
 a primary foot member extending from a heel portion to a toe portion of the foot;   a shock absorbing heel member extending downward from an underside of the primary foot member;   at least one tendon extending from the heel member and connecting to a more forward portion of the primary foot member; and   a connecting element extending upward from a top surface of the heel portion of the primary foot member;   wherein at least the primary foot member, the heel member, and at least one tendon are a unitary structure produced by an additive manufacturing process.   
     
     
         2 . The prosthetic foot of  claim 1 , wherein the toe portion of the primary foot member is divided into two toe sections and a separate tendon extends outward from the heel member and respectively connects to the primary foot member near each toe section. 
     
     
         3 . The prosthetic foot of  claim 1 , wherein the toe portion of the primary foot member is divided into two toe sections separated by a gap, wherein one or more connecting bands pass from one toe section to the other toe section and span the gap. 
     
     
         4 . The prosthetic foot of  claim 1 , wherein the heel member is substantially hollow and includes a plurality of apertures that pass through a sidewall portion thereof. 
     
     
         5 . The prosthetic foot of  claim 1 , wherein the connecting element comprises a plurality of grouped rods surrounded by an elastomeric band, with one end of each rod attached to the primary foot member. 
     
     
         6 . The prosthetic foot of  claim 1 , wherein the connecting element comprises a torsional pylon including a plurality of grouped rods produced by an additive manufacturing process. 
     
     
         7 . The prosthetic foot of  claim 1 , wherein the connecting element comprises a torsional pylon including a plurality of grouped rods encircled by an elastomeric band, wherein a stiffness of the elastomeric band can be selected to control a stiffness of the torsional pylon. 
     
     
         8 . The prosthetic foot of  claim 1 , further comprising a hollow foot shell configured to be placed on the prosthetic foot. 
     
     
         9 . A prosthetic foot comprising:
 a primary foot member extending from a heel portion to a toe portion of the foot;   a shock absorbing heel member extending downward from an underside of the primary foot member; and   at least one tendon extending from the heel member and connecting to a more forward portion of the primary foot member;   wherein at least one of the primary foot member, the heel member, and at least one tendon are a unitary structure produced by an additive manufacturing process.   
     
     
         10 . The prosthetic foot of  claim 9 , further comprising a connecting element extending upward from a top surface of the heel portion of the primary foot member. 
     
     
         11 . The prosthetic foot of  claim 9 , wherein the toe portion of the primary foot member is divided into two toe sections and a separate tendon extends outward from the heel member and respectively connects to the primary foot member near each toe section. 
     
     
         12 . The prosthetic foot of  claim 9 , wherein the toe portion of the primary foot member is divided into two toe sections separated by a gap, wherein one or more connecting bands pass from one toe section to the other toe section and span the gap. 
     
     
         13 . The prosthetic foot of  claim 9 , wherein the heel member is substantially hollow and includes a plurality of apertures that pass through a sidewall portion thereof. 
     
     
         14 . The prosthetic foot of  claim 10 , wherein the connecting element is comprised of a plurality of grouped rods surrounded by an elastomeric band, with one end of each rod attached to the primary foot member. 
     
     
         15 . The prosthetic foot of  claim 10 , wherein the connecting element comprises a torsional pylon including a plurality of grouped rods produced by an additive manufacturing process. 
     
     
         16 . The prosthetic foot of  claim 10 , wherein the connecting element comprises a torsional pylon including a plurality of grouped rods encircled by an elastomeric band, wherein a stiffness of the elastomeric band can be selected to control a stiffness of the torsional pylon. 
     
     
         17 . The prosthetic foot of  claim 9 , further comprising a hollow foot shell configured to be placed on the prosthetic foot. 
     
     
         18 . A prosthetic foot comprising:
 a primary foot member extending from a heel portion to a toe portion of the foot;   a shock absorbing heel member extending downward from an underside of the primary foot member;   at least one tendon extending from the heel member and connecting to a more forward portion of the primary foot member; and   a connecting element extending upward from a top surface of the heel portion of the primary foot member, the connecting element comprising a plurality of grouped rods surrounded by an elastomeric band;   wherein at least the primary foot member, the heel member, at least one tendon, and the plurality of grouped rods are produced by an additive manufacturing process.   
     
     
         19 . The prosthetic foot of  claim 18 , wherein the connecting element comprises a torsional pylon including the plurality of grouped rods produced by an additive manufacturing process. 
     
     
         20 . The prosthetic foot of  claim 18 , wherein the connecting element comprises a torsional pylon including a plurality of grouped rods encircled by an elastomeric band, wherein a stiffness of the elastomeric band can be selected to control a stiffness of the torsional pylon.