Integrated Design Approach For Multi-Material Additive Manufacturing Of High-Strength Biocompatible Prosthetics

18 May
Posted on Author

Authors: Ms. Aishvarya Thombare, Dr. Dilip Gangwani

Abstract: Additive manufacturing enables patient-specific prosthetic devices with complex geometries; however, single-material prints rarely meet concurrent requirements of stiffness, durability, and comfort. This study develops a low-similarity, citation-backed framework for multi-material 3D printed, load-bearing prosthetics. A region-wise material allocation strategy is proposed using PLA for structural shells, TPU for compliant interfaces, and carbon fiber–reinforced polymer (CFRP) for primary load paths. Finite Element Analysis (FEA) with validated boundary conditions (800–1500 N) and topology optimization are employed to minimize mass under stress constraints. Experimental validation (ASTM D638/D695) confirms a 31.8% increase in load capacity and a 23.6% reduction in deformation versus single-material PLA. The combined design–analysis workflow demonstrates improved fatigue resistance and user comfort while maintaining manufacturability.

DOI: http://doi.org/10.5281/zenodo.20268038