• CAD-FEA pipeline evaluated lattice-integrated transfemoral sockets. • Solid PLA sockets showed 37% greater flexibility than carbon fibre. • Lattice integration reduced socket weight by up to 14% without plastic deformation. • BCC lattices optimised stress balance and flexibility under physiological load. • Computer-aided design enables lighter, patient-tailored prosthetic sockets. Transfemoral prosthetic sockets are essential for mobility, yet conventional designs remain rigid, labour-intensive and often inaccessible. Additive manufacturing offers a promising pathway for rapid, cost-effective production of personalized sockets through lattice integration, but their biomechanical implications remain underexplored. This study employed a CAD-FEA workflow to evaluate the mechanical performance of Polylactic Acid (PLA) sockets—selected for its accessibility and Material Extrusion (MEX) compatibility—under physiological loading. Lattice structures (BCC, FCC, Diamond) were embedded within a patient-specific model, with structures varying in their relative density (20–50%), and placement; lattice selection and their parameters were constrained by preliminary print trials and fabrication resolution to ensure practical manufacturability. Solid PLA socket exhibited stress distributions comparable to carbon-fibre but with 37% higher displacement, indicating improved flexibility. Lattice integration reduced weight by 6–14%. BCC lattice sockets achieved the best balance between stress distribution and compliance, while FCC designs maximized weight reduction but increased stress concentrations (up to 31.14 MPa). Increasing relative density and optimizing lattice placement effectively minimized peak stresses. These results demonstrate that strategic lattice integration provides a manufacturable, transferable framework for lighter, mechanically efficient, and personalized prosthetic sockets, advancing next-generation biomechanical systems.
Vignon-Whaley et al. (2026) studied this question.