Additive Manufacturing of Patient–Specific Lattice Prosthetic Sockets via Field–Driven Design and Elastic–Plastic Homogenization

The development of patient-specific prosthetic sockets requires the integration of clinical data with advanced design methodologies to ensure both comfort and mechanical reliability. In this work, we propose a digital workflow combining 3D scanning of the residual limb, anatomical reconstruction, and computational design. The approach integrates elastic–plastic homogenization with a Field-Driven Design (FDD) strategy, where stress fields obtained from finite element analysis are mapped to spatially varying lattice properties and geometries. This approach enables a direct stress-to-structure transition for the design of lightweight, graded lattice sockets. The methodology is applied to a personalized socket manufactured via Multi Jet Fusion in PA12. Numerical simulations and experimental testing of a full-scale prototype demonstrate a weight reduction of up to 25% compared to a solid design, while maintaining a robust safety factor. Computed tomography analysis confirms good agreement between the as designed and as-built geometries. The proposed framework highlights the potential of integrating clinical data and Field-Driven lattice Design for next-generation and personalized prosthetic devices.