Developing transtibial cycling-specific prostheses through additive manufacturing

A long period of recovery follows any amputation surgery, where complications such as reduced mobility, depression, and body image distortion often result in amputees having significantly less active lifestyles than they did prior. Sporting activities can bring many benefits to recovery including, social interaction and motor skill development, yet, there are significant physical, social and financial barriers for people to participate. Para-Cycling is considered a low impact exercise and an excellent activity for lower limb amputees. However, using conventional walking prostheses for cycling can create short- and longer-term difficulties by increasing the strain on the residual limb. Through a combination of user-collaborative engagements, the design and development of prototypes, analysis and application of additive manufacturing process, and digital data-driven design methods, this research seeks to design a prosthesis for transtibial lower limb amputees who want to cycle. The research results in the design of a series of a custom-made prosthetic components for the needs of amputee rehabilitation and their participation in sport. It proposes a new design approach to cycling-specific prostheses, and design-led insights for prosthetics design.