Additive manufacturing techniques for protective devices, prosthetics, and orthotics

Abstract

A lower extremity prosthetic socket, according to some embodiments. The lower extremity prosthetic socket includes a shell having variable thickness along a longitudinal length of the shell. The lower extremity prosthetic socket is configured to provide stability for a residual limb of a user when worn by the user. The lower extremity prosthetic socket is configured to distribute forces. The shell is configured to conform to an anatomical structure of the residual limb of the user.

What is claimed is: 
     
         1 . A lower extremity prosthetic socket comprising:
 a shell having variable thickness along a longitudinal length of the shell;   wherein the lower extremity prosthetic socket is configured to provide stability for a residual limb of a user when worn by the user;   wherein the lower extremity prosthetic socket is configured to distribute forces; and   wherein the shell is configured to conform to an anatomical structure of the residual limb of the user.   
     
     
         2 . The lower extremity prosthetic socket of  claim 1 , wherein the lower extremity prosthetic socket is an above-the-knee (AK) prosthetic socket or a below-the-knee (BK) prosthetic socket. 
     
     
         3 . The lower extremity prosthetic socket of  claim 1 , wherein the shell is configured to fully receive the residual limb of the user within an inner volume of the shell. 
     
     
         4 . The lower extremity prosthetic socket of  claim 1 , wherein the shell is configured to undergo deformation without sustaining structural damage. 
     
     
         5 . The lower extremity prosthetic socket of  claim 4 , wherein an amount of the deformation or flexion at a particular position along the shell is inversely proportional to a thickness at the particular position along the shell. 
     
     
         6 . The lower extremity prosthetic socket of  claim 1 , wherein a thickness of the shell at a first longitudinal position is different than a thickness of the shell at a second longitudinal position to accommodate for differences in the anatomical structure of the residual limb of the user. 
     
     
         7 . The lower extremity prosthetic socket of  claim 1 , wherein the variable thickness corresponds to unique anatomical structures of the residual limb of the user or requests of the user or a health care provider. 
     
     
         8 . A method for manufacturing a lower extremity prosthetic socket, the method comprising:
 using a digital scanner to capture either an anatomical structure of a patient's distal limb or an anatomical structure of a cast of the patient's distal limb to generate a scan file;   converting the scan file to a design file;   modifying the design file; and   additively manufacturing the design file to produce the lower extremity prosthetic socket using an additive manufacturing device.   
     
     
         9 . The method of  claim 8 , wherein modifying the design file comprises using build-ups or reductions to a thickness of a shell of the design file. 
     
     
         10 . The method of  claim 8 , wherein the lower extremity prosthetic socket comprises variable thickness along a dimension of the lower extremity prosthetic socket. 
     
     
         11 . The method of  claim 10 , wherein the variable thickness is configured to accommodate the anatomy of the residual limb of the patient. 
     
     
         12 . The method of  claim 8 , wherein the design file is at least one of a computer assisted design (CAD) file or a computer assisted manufacturing (CAM) file. 
     
     
         13 . The method of  claim 8 , wherein the additive manufacturing device is a 3d printer configured to output layers of material on top of each other in succession to produce the lower extremity prosthetic socket. 
     
     
         14 . The method of  claim 8 , further comprising uploading the design file to the additive manufacturing device. 
     
     
         15 . A lower extremity prosthetic socket comprising:
 a shell having variable thickness along a longitudinal length of the shell, the variable thickness configured to provide a thicker region at areas of higher expected stress and a thinner region at areas of lower expected stress;   wherein the shell is manufactured by additive manufacturing.   
     
     
         16 . The lower extremity prosthetic socket of  claim 15 , wherein the lower extremity prosthetic socket is configured to provide stability for a residual limb of a user when worn by the user. 
     
     
         17 . The lower extremity prosthetic socket of  claim 15 , wherein the shell is configured to conform to an anatomical structure of the residual limb of the user. 
     
     
         18 . The lower extremity prosthetic socket of  claim 15 , wherein a thickness of the shell at a first longitudinal position is different than a thickness of the shell at a second longitudinal position to accommodate for differences in the anatomical structure of the residual limb of the user. 
     
     
         19 . The lower extremity prosthetic socket of  claim 15 , wherein the variable thickness corresponds to unique anatomical structures of the residual limb of the user or requests of the user or a health care provider. 
     
     
         20 . The lower extremity prosthetic socket of  claim 15 , wherein the lower extremity prosthetic socket is an above-the-knee (AK) prosthetic socket or a below-the-knee (BK) prosthetic socket.