Design and Analysis of Prosthetic Foot using Additive Manufacturing Technique

International Journal of Trend in Scientific Research and Development (IJTSRD)
Volume 5 Issue 5, July-August 2021 Available Online: www.ijtsrd.com e-ISSN: 2456 – 6470
@ IJTSRD | Unique Paper ID – IJTSRD45044 | Volume – 5 | Issue – 5 | Jul-Aug 2021 Page 1262
Design and Analysis of Prosthetic Foot using
Additive Manufacturing Technique
Mr. Akshay Dashrath Mule, Prof. Dr. P. M. Bagade
Padmabhooshan Vasantraodada Patil Institute of Technology, Bavdhan, Pune, Maharashtra, India
ABSTRACT
Prosthetic feet are designed for an individual's foot at a particular
activity level. Prosthetic foot is a style for people that cannot walk,
the performance is basically cosmetic. For people who square
measure most actively, a prosthetic foot should mimic a traditional
foot throughout the act of walking. The fabric for prosthetic feet
varies by varied use of foot and by varied application. Wood, plastic
and foam are sometimes found in feet designed for people who have
low activity levels and need stability. Carbon fiber feet meet the
purposeful wants for shock absorption and energy potency, and
square measure light-weight further. a variety of metals square
measure used for prosthetic limbs; Al, Titanium, Magnesium,
Copper, Steel, and lots of additional. titanium was discovered within
the late eighteenth century. It's a typical metal used for medical and
engineering applications due to its several favorable properties. it's
sensible strength to weight quantitative relation, guck strength to
density quantitative relation, glorious corrosion resistance, density
and it's light-weight. So, perform static and model analysis on
existing prosthetic foot to seek out stresses, total deformation. Then
replace the fabric with the 3D printing additive producing technique.
And find out the analysis result and compare the prevailing. Then
experimental testing may be carried out to validate the result.
KEYWORDS: Design optimization, Prosthetic feet, 3 Point bending
test, UTM
How to cite this paper: Mr. Akshay
Dashrath Mule | Prof. Dr. P. M. Bagade
"Design and Analysis of Prosthetic Foot
using Additive Manufacturing
Technique" Published in International
Journal of Trend in
Scientific Research
and Development
(ijtsrd), ISSN: 2456-
6470, Volume-5 |
Issue-5, August
2021, pp.1262-
1269, URL:
www.ijtsrd.com/papers/ijtsrd45044.pdf
Copyright © 2021 by author (s) and
International Journal of Trend in
Scientific Research and Development
Journal. This is an
Open Access article
distributed under the
terms of the Creative Commons
Attribution License (CC BY 4.0)
(http://creativecommons.org/licenses/by/4.0)
I. INTRODUCTION
Over the past decade, technology and analysis have
greatly enlarged the practicality and aesthetics of
prosthetic feet. Today, amputees have a large array of
feet from that to decide on. varied models square
measure designed for activities starting from walking,
performing arts and running to athletics, golfing,
swimming and even snow sport. Heavier wood and
steel materials are replaced over the years by light-
weight plastics, metal alloys and carbon-fiber
composites. Very like the vertebrate foot, several of
today’s prosthetic feet will store and come back a
number of the energy generated throughout walking.
different key attributes enclosed toe and heel springs
that enable a lot of natural movement at the ankle
joint, shock absorption, multi-axial rotation,
adjustable heel heights, and waterproof materials. Fig. Prosthetic foot
IJTSRD45044

International Journal of Trend in Scientific Research and Development @ www.ijtsrd.com eISSN: 2456-6470
Prosthetic feet can be categorized into the following
groups:
Solid Ankle Cushioned Heel (SACH)
Elastic (flexible) Keel Foot
Single-Axis Foot
Multi-Axis Foot
Dynamic-Response Foot
Microprocessor Foot.
The most basic prosthetic feet are available in 2
types: Solid ankle cushioned Heel (SACH) and
Elastic Keel configurations. These styles contain
crepe synthetic rubber or ester foam shaped over
associate degree inner keel and formed to jibe a
personality's foot. as a result of they need no hinged
elements, these basic feet are comparatively cheap,
sturdy and just about maintenance-free. These feet
provide artifact and energy absorption however don't
store and come with identical quantities of energy as
dynamic-response feet. SACH and elastic keel feet
are usually prescribed for amputees. The United
Nations agency does a restricted quantity of walking
with very little variation in speed.
SACH Foot: The SACH is the simplest form of non-
articulated foot. The name refers to a somewhat soft
rubber heel wedge that mimics articulation
talocruralis action by pressing underneath load
throughout the first part of the stance section of
walking. The keel is rigid, and provides instance
stability with very little lateral movement. The SACH
foot is offered in varied heel heights to match
individual shoes with completely different heel
heights. Elastic (flexible) Keel Foot:
This prosthetic foot permits motion like that of SACH
feet. additionally, the foot is in a position to adapt to
uneven tract however remains adjunct and stable
throughout standing and walking.
Fig. Concept of foot
II. LITERATURE REVIEW
Hongshen F. Britesa, C. Malçaa,, F. Gaspara, J. F.
Hortaa, M. C. Francoa, S. Biscaiaa, A. Mateus.
et.al[1], In this exploration work, plastic networks of
HDPE – got from ordinary providers – were built up
with various proportions of stopper waste and normal
plug powders – acquired from stopper change
enterprises – to track down the ideal combination for
3D printing. The impacts of plug powders content in
the plastic on the morphological, physical and
mechanical properties of the composites were
researched through the thickness, optical microscopy,
wettability, warm investigation and tractable testing.
Stopper based composites were prepared by an
expulsion framework, and the combination of
polymer, glue and fillers is examined. The outcomes
show that the expansion of unadulterated stopper and
plug waste can be prepared with polymers like
HDPE, having sufficient physical and mechanical
properties. One of the motivations behind this work
was to think about the impact of various plug
powders blended in with a HDPE lattice. The
outcomes taken from the stopper powders thickness
estimations showed that plug squander thickness is
higher than the unadulterated plug, prompting higher
sum unadulterated plug in the composites
combination than for the composites with plug
squander. A higher level of plug waste can in this
manner be added to the polymer framework.
Tiantian Li, Lifeng Wang, et.al[2], This paper centers
around to consolidate 3D printing strategy,
mathematical examination, and analyses to plan
another class of sandwich composites that display
different bowing practices. These customized
sandwich structures contain 3D printed center
materials with support, regular honeycomb, and re-
contestant honeycomb geographies. Three-point
twisting tests are performed to explore the bowing
conduct of these sandwich composites with two kinds
of carbon fiber built up polymer face sheets. Under
bowing twisting, sandwich composites with bracket
center materials give most elevated extramural
solidness and strength that are alluring in primary
segments. The sandwich composites with re-
participant honeycomb center display a successive
snap-through flimsiness which altogether improves
the energy retention capacities. Our trial and
mathematical outcomes demonstrate that architect ed
center designs can be used to tailor the bowing
properties just as disappointment systems. These
discoveries offer new bits of knowledge into the
investigation of nonlinear mechanical reaction of
sandwich structures, which can profit a wide scope of
businesses and applications.
Aman Sharma, Harish Garg. et.al[3], This paper is
about the trend setting innovation of 3D printing,
their execution in the individual fields and its critical
commitment in the worldwide universe of science and

clinical. In this paper we will manage the term
Additive Manufacturing or 3D Printing and a
smidgen of its set of experiences. Its different
applications alongside the kind of materials utilized in
the 3-D are likewise depicted. We will likewise
illuminate the various chances given by this arising
innovation just as the dangers and difficulties
identified with it. Its ecological viewpoints are
additionally displayed in the paper. Ultimately the
degree and situation in future capability of 3D
printing is additionally assessed.
Masaaki TSUTSUBUCHI, Tomoo HIROTA,
Yasuhito NIWA, Tai SHIMASAKI. et.al[4], This
paper traces the application patterns and investigation
procedures followed by a clarification of the
trademark physical properties of tars which might be
the central issues for their functional application.
Given the quick progression in PC execution, which
has extended the size of calculation, the contribution
of nitty gritty part data in regards to part
arrangements has gotten moderately basic. The
utilization of more nitty gritty models is additionally
gradually becoming mainstream for material models
which have considered disentanglement to be one of
the consequences of more limited calculation time.
Sumitomo Chemical likewise plans to join CAE for
item plan with CAE for polymer plan later on.
Zhen Chen. et.al[5], According to this paper as of late
3D printing innovation is growing quickly. Soon,
when 3D printing is generally utilized, the world's
mechanical design will be incredibly changed. In light
of the genuine information, this paper builds a
worldwide store network model utilizing framework
elements technique. What's more, it reproduces the
recreation pattern of the inventory network after 3D
printing application. The end shows that the
widespread utilization of 3D printing will prompt the
overall vehicle volume contracting drastically. The
assembling exercises will continuously surge to the
nations which are nearer to the last clients. The
pertinent nations should do doable measures to
confront this chance and challenge. The actions
incorporate the change of coordinations offices, the
coordinations participation with the beginning of 3D
printing materials, and the coordinated with
transportation of 3D printing materials and
conventional handling ones.
N. Shahrubudin, T. C. Lee, * R. Ramlan. et.al[6], In
this survey paper, there are rich scene of 3D
imprinting in assembling industry. As of now, 3D
printing innovation is starting in the assembling
businesses, it offers numerous advantages to
individuals, organization and government. Thusly,
more data is expected to advance on approaches to
upgrade the selection of 3D printing innovation. The
more data about 3D printing innovation will help the
organization and government to redesign and work on
the framework of 3D printing innovation.
Subsequently, this paper is to outline the kinds of 3D
printing advances, materials utilized for 3D printing
innovation in assembling industry and finally, the
uses of 3D printing innovation. Later on, specialists
can do some examination on the sort of 3D printing
machines and the appropriate materials to be utilized
by each kind of machine.
Vinod G. Gokhare, Dr. D. N. Raut, Dr. D. K. Shinde.
et.al[7], This is an exploration paper on 3D printing
and the different materials utilized in 3D printing and
their properties which become an eminent subject in
innovative viewpoints. In the first place, characterize
what is implied by 3D printing and what is huge of
3D printing. They will go into the historical backdrop
of 3D printing and learn about the cycle of 3D
printing and what materials utilized in the assembling
of 3D printed protests and select the best materials
among them which are reasonable for our 3D printing
machine. Likewise, see the upsides of 3D printing
when contrasted with added substance producing.
Tianyun Yao, Zichen Deng, Kai Zhang, Shiman Li.
et.al[8], In this paper to advance the mechanical
examination and plan of 3D printing structures, a
definitive rigidity of FDM PLA materials with
various printing points were concentrated
hypothetically and tentatively. A hypothetical model
was initially settled to anticipate a definitive elasticity
of FDM PLA materials dependent on cross over
isotropic speculation, traditional cover hypothesis and
Hill-Tsai anisotropic yield measure, and afterward
checked by ductile trials. Contrasted and past models,
this model gave two sorts of in-plane shear modulus
estimation strategies, so the computation results were
more dependable. The examples, planned by the
current plastic-multipurpose test examples standard
ISO 527-2-2012, were imprinted in seven distinct
points with three layer thicknesses (0. 1 mm, 0. 2 mm,
0. 3 mm) for each point. The overall lingering amount
of squares between hypothetical information and
exploratory information were all near nothing, so the
outcomes that the hypothetical model can precisely
foresee a definitive elasticity of FDM materials for all
points and thicknesses were affirmed.
Michael Dawoud, ImanTaha, Samy J. Ebeid. et.al[9],
In this paper Carbon Black filled Acrylonitrile
Butadiene Styrene (ABS) was utilized to set up a
polymer composite by Fused Deposition Modeling
(FDM) innovation. The impact of printing
arrangement on the strain detecting conduct of the
composite was examined, focusing on the creation of

a fictionalized composite that can distinguish pressure
or strain changes in designing individuals. Test work
uncovered that inner anxieties can be identified
dependent on observing the adjustment of obstruction
as a reaction to strain. Estimations across test
thickness were discovered to be generally reasonable
for offering general expressions about the resistivity
of the examples
Aubrey L. Woern, Joseph R. McCaslin, Adam M.
Pringle, Joshua M. Pearce. et.al[10], This paper
portrays the plan, manufacture and activity of a
RepRapable Recyclebot, which alludes to the Recycle
bot's capacity to give the fiber expected to generally
repeat the parts for the Recyclebot on a RepRap 3-D
printer. The gadget costs under $700 in mate rials and
can be created in around 24 h. Fiber is delivered at 0.
4 kg/h utilizing 0. 24 kWh/kg with a distance across
±4. 6%. Hence, fiber can be made from business
pellets for <22% of business fiber costs.
Edwin L. Thomas, and Mary C. Boyce. et.al[11 ],
According to this paper two-part requested
constructions wherein the two stages are strong and
persistent (co-consistent strong designs) are un
normal in nature and in business applications. Regular
and manufactured co-consistent designs, involved
hard and delicate materials can give remarkable
mixes of properties including solidness, strength,
sway obstruction, durability, and energy dispersal.
The mathematical and topological plan of the
constituents gives roads to design the macro scale
properties. Different compound handling courses and
advances currently empower the exact creation of
requested co-ceaseless microstructure materials over
a wide scope of length scales.
III. PROBLEM STATEMENT
Numerous prosthetic leg designs are available with
various materials and functions. Although prosthetic
foot is popular, the standard design is not established
yet. This is due to the dedicated function. The cost of
Existing foot is high and there are some cases that
facing failure issue in prosthetic foot. Due to
increased foot loss due to accident and increased foot
amputation rate due to malignancy or gangrene, the
demand for new prosthetic foot is also increasing. So
we decide to varying material of prosthetic foot for
improving performance.
IV. OBJECTIVES
The main objective is to analyze the prosthetic
foot structure and find out results.
Using additive manufacturing technique to
manufacture prosthetic foot.
Study on 3D printing technologies
Find out better material use for prosthetic foot
using ANSYS software.
Experimental validation of optimized prosthetic
foot.
FEA OF PROSTHETIC FOOT
GEOMETRY
Fig. Geometry
Fig. Material properties of plastic
Fig. Material properties of ABS
Fig. Material properties of PLA
Meshing
Meshing is an integral part of the computer-aided
engineering simulation process. The mesh influences
the accuracy, convergence and speed of the solution.
Furthermore, the time it takes to create and mesh a
model is often a significant portion of the time it takes
to get results from a CAE solution. Therefore, the

better and more automated the meshing tools, the
better the solution.
Fig. Meshing details
Boundary Condition
A boundary condition for the model is the setting of a
known value for a displacement or an associated load.
For a particular node you can set either the load or the
displacement but not both.
Fig. Boundary condition
The prosthetic foot we selected is use for child, age
between 4 to 18. The maximum weight of child
between this age is 75 kg.
By considering factor of safety 1. 2 the weight we
applied on prosthetic foot is 90kg.
Force = 90 X 9. 81
= 900 N
RESULTS PLOT
Results for plastic material
Total deformation
The total deformation & directional deformation are
general terms in finite element methods irrespective
of software being used.
Fig. Total deformation
Equivalent Stress
Fig. Equivalent stress
Results for ABS material
Total deformation
Fig. Total deformation for ABS material

Fig. Equivalent stress for ABS material
Results for PLA material
Total deformation
Fig. Total deformation for PLA material
Fig. Equivalent stress
EXPERIMENTAL VALIDATION:
A Universal Testing Machine (UTM) is used to test
both the tensile and compressive strength of
materials. Universal Testing Machines are named as
such because they can perform many different
varieties of tests on an equally diverse range of
materials, components, and structures.
Universal Testing Machines can accommodate many
kinds of materials, ranging from hard samples, such
as metals and concrete, to flexible samples, such as
rubber and textiles. This diversity makes the
Universal Testing Machine equally applicable to
virtually any manufacturing industry.
The UTM is a versatile and valuable piece of testing
equipment that can evaluate materials properties such
as tensile strength, elasticity, compression, yield
strength, elastic and plastic deformation, bend
compression, and strain hardening. Different models
of Universal Testing Machines have different load
capacities, some as low as 5kN and others as high as
2, 000kN.
SPECIFICATION OF UTM
1 Max Capacity 400KN
2 Measuring range 0-400KN
3 Least Count 0.04KN
4
Clearance for Tensile
Test
50-700 mm
5
Clearance for
Compression Test
0- 700 mm
6
Clearance Between
column
500 mm
7 Ram stroke 200 mm
8 Power supply
3 Phase, 440Volts,
50 cycle. A.C
9
Overall dimension of
machine (L*W*H )
2100*800*2060
10 Weight 2300Kg
Fig. Experimental testing of foot

Fig. Experimental results
As per experimental test we applied the 900 N load
on the prosthetic foot and find out the deformation
observed in the foot. The maximum deformation
observed is 13 mm approximately.
CONCLUSION
Study on 3D printing technologies and additive
manufacturing process. Learn about prosthetic
foot and material used for prosthetic foot and
different application of foot.
Perform static analysis of prosthetic foot using
Static structural tool with the help of ANSYS
software.
Perform static analysis to find out total
deformation and equivalent stress generated on
prosthetic foot using different materials. Existing
material used for manufacturing prosthetic foot
for child is plastic. We replace this material with
PLA and ABS.
The total deformation and equivalent stress using
different material is as given below
Sr.
No
Material
Used
Equivalent
Stress
(Mpa)
Total
Deformation
(Mm)
Weight
(Kg)
1 PLASTIC 63.92 41.09 0.329
2 ABS 64.36 13.45 0.36
3 PLA 64.44 23.65 0.429
Fig. Comparison of equivalent stress
Fig. Comparison of total deformation
Fig. Weight comparison
REFERENCES
[1] F. Britesa, C. Malçaa, F. Gaspara, J. F. Hortaa,
M. C. Francoa S. Biscaiaa, A. Mateus “Cork
Plastic Composite Optimization for 3D Printing
Applications”.
[2] Tiantian Li, Lifeng Wang “Bending behavior of
sandwich composite structures with tunable
3D-printed core materials”.
[3] Aman Sharma, Harish Garg. “Utility and
challenges of 3 D Printing”.
[4] Masaaki TSUTSUBUCHI, Tomoo HIROTA,
Yasuhito NIWA, Tai SHIMASAKI
“Application of Plastics CAE: Focusing on
Impact Analysis”.
[5] Zhen Chen“Research on the Impact of 3D
Printing on the International Supply Chain”.
[6] N. Shahrubudin, T. C. Lee, R. Ramlan“An
Overview on 3D Printing Technology:
Technological, Materials, and applications”
[7] “A Review paper on 3D-Printing Aspects and
Various Processes Used in the 3D-Printing” by
Vinod G. Gokhare, Dr. D. N. Raut, Dr. D. K.
Shinde.
[8] Tianyun Yao, Zichen Deng, Kai Zhang, Shiman
Li “A method to predict the ultimate tensile
strength of 3D printing polylactic acid (PLA)
materials with different printing orientations”.

[9] Michael Dawoud, Iman Taha, Samy J. Ebeid
“Strain sensing behaviour of 3D printed carbon
black filled ABS”.
[10] Aubrey L. Woern, Joseph R. McCaslin, Adam
M. Pringle, Joshua M. Pearce “RepRapable
Recyclebot: Open source 3-D printable extruder
for converting plastic to 3-D printing filament”.
[11] Lifeng Wang, Jacky Lau, Edwin L. Thomas,
and Mary Boyce “Co-Continuous Composite
Materials for Stiffness, Strength, and Energy
Dissipation”.

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