Abstract: An interconnection component or an adaptor bracket for use in coupling a distal end of a prosthetic limb socket to a proximal end of an endoskeletal component of a prosthetic limb, where the interconnection component is specifically adapted to compensate for a patient's flexion contracture.

Abstract: A shuttle-lock for maintaining a patient's residual limb in a prosthetic limb socket includes: (a) a housing having a distal surface adapted to abut an inside surface of a prosthetic limb socket, a substantially concave proximal surface and a hole extending into the center of the proximal surface, where the hole is adapted to receive a plunger pin carried on a patient's residual limb therein; and (b) a lock positioned within the housing for securing the plunger pin received in the hole where the concave proximal surface includes a plurality of radially extending grooves that are adapted to guide the plunger pin into the hole.

Abstract: The present invention facilitates the use of the rapid manufacturing systems in the manufacture of prosthetic limb sockets by providing a substantially flat and strong distal attachment plate or base for the deposition of the fused-deposition-modeling materials thereon. The present invention also provides a method for fabricating a socket of a prosthetic limb which comprises the steps of: (a) providing a substantially flat distal attachment plate, where the attachment plate includes a coupling mechanism carried thereon for coupling a prosthetic upright assembly thereto; and (b) repeatedly depositing layers of solidifying material to the proximal surface of the attachment plate, controlled, at least in part, according to the dimensions of the patient's residual limb, so as to form a socket for receiving the patient's residual limb.

Abstract: A plunger pin assembly for locking engagement with a shuttle lock of a prosthetic limb socket assembly, includes: (a) a housing having an internal cavity and a center-hole extending into its distal end, communicating with the internal cavity; (b) a cradle retained within the cavity, having a distal-facing outer surface that is laterally slidable with respect to the proximal-facing inner surface of the cavity, where the cradle includes a plunger pin component extending distally therefrom; and (c) a resilient shock absorber positioned, at least partially, between the proximal end of the plunger pin component and the inner distal-facing surface of the cavity; where (d) the cradle includes a center hole extending axially therethrough, the plunger pin component includes a ball positioned on a proximal end thereof, the ball having a diameter larger than the diameter of the center hole of the cradle, and the ball of the plunger pin component is seated in the center hole of the cradle to provide a ball joint coupling

Abstract: A mandrel, and a method using a mandrel, for fabricating a cosmetic cover for a prosthetic limb having a socket for placement over a wearer's residual limb and having a component positioned outside, and attached to, the socket through aligned holes of the component and the socket. The mandrel has a mandrel plate attached to a mandrel shaft. The mandrel plate has holes aligned with the holes of the socket so the mandrel plate may be attached to the socket and the component thereby supporting the prosthetic limb. The mandrel shaft is placed in a chuck of a milling machine when the supported prosthetic limb, with an attached cosmetic cover blank, is attached to the mandrel plate, and the outside surface of the cosmetic cover blank is milled to match a mirror image of the wearer's sound limb.

Abstract: A coupling-socket adapter assembly for a prosthetic limb. A base plate subassembly is attachable to a first prosthetic limb component. A coupling-socket adapter is rotatably attached to the base plate subassembly and has a cavity for receiving a male coupling member (such as a boss of a pyramidal link-plate). Various mechanisms, including a ring having internal threads and including a ring-clamp, are disclosed for locking the coupling-socket adapter against rotation with respect to the base plate subassembly and for unlocking the coupling-socket adapter for rotation with respect to the base plate subassembly, wherein the mechanisms are operable when the base plate subassembly is attached to the first prosthetic limb component.

Abstract: A shuttle lock for maintaining a patient's residual limb in a prosthetic limb socket includes: (a) a housing having a distal surface adapted to abut an inside surface of a prosthetic limb socket, a substantially concave proximal surface and a hole extending into the center of the proximal surface, where the hole is adapted to receive a plunger pin carried on a patient's residual limb; (b) a lock positioned within the housing for securing the plunger pin received in the hole; and (c) means for securing the housing of the shuttle lock within the prosthetic limb socket; (d) where the concave proximal surface includes at least one radial groove which is adapted to guide the plunger pin into the hole.

Abstract: The present invention facilitates the use of the rapid manufacturing systems in the manufacture of prosthetic limb sockets by providing a substantially flat and strong distal attachment plate or base for the deposition of the fused-deposition-modeling materials thereon. The present invention also provides a method for fabricating a socket of a prosthetic limb which comprises the steps of: (a) providing a substantially flat distal attachment plate, where the attachment plate includes a coupling mechanism carried thereon for coupling a prosthetic upright assembly thereto; and (b) repeatedly depositing layers of solidifying material to the proximal surface of the attachment plate, controlled, at least in part, according to the dimensions of the patient's residual limb, so as to form a socket for receiving the patient's residual limb.

Abstract: A pyramidal link-plate assembly for coupling a prosthetic limb upright assembly to another prosthetic limb component includes: a base plate member having a dome extending from a distal end and a cavity opening onto a distal apex of the dome, where the cavity includes a conically shaped portion with a diameter that widens with the distance from the distal apex of the dome; and a rotatable member which includes a substantially conically shaped body positioned within the conical portion of the cavity and which includes a frustopyramidal boss extending distally therefrom out through the opening in the distal apex of the dome. The conically shaped body of the rotatable member, positioned within the cavity, also widens with the distance from the distal apex of the dome. The boss is adapted to be received within an a central opening of a conventional annular coupling-socket.

Abstract: A prosthetic foot comprises: (a) a prosthetic foot member having a fore-foot portion and a heel/ankle portion; (b) a dove-tail shaped anchoring member positioned on a proximal surface of the heel/ankle portion, where the dove-tail shaped anchoring member has a proximal face, and a pair of outwardly angled vertical faces; (c) a pylon support member having an upper end adapted to receive and couple to a pylon component of a prosthetic limb, and a lower end with a dove-tail shaped groove extending therein, where the dove-tail shaped groove has a pair of inwardly angled vertical faces and an inner-distal face, and where the dove-tail shaped anchoring member is slidingly received within the dove-tail shaped groove of the pylon support member; and (d) a threaded coupler cooperative with the dove-tail shaped anchoring member to draw the inwardly angled vertical faces of the pylon support member into an interference fit with the outwardly angled faces of the dove-tail shaped anchoring member, thereby inhibiting slidi

Abstract: A pyramidal link-plate assembly for coupling a prosthetic limb upright assembly to another prosthetic limb component includes: a base plate member having a dome extending from a distal end and a cavity opening onto a distal apex of the dome, where the cavity includes a conically shaped portion with a diameter that widens with the distance from the distal apex of the dome; and a rotatable member which includes a substantially conically shaped body positioned within the conical portion of the cavity and which includes a frustopyramidal boss extending distally therefrom out through the opening in the distal apex of the dome. The conically shaped body of the rotatable member, positioned within the cavity, also widens with the distance from the distal apex of the dome. The boss is adapted to be received within an a central opening of a conventional annular coupling-socket.

Abstract: The present invention provides a method and apparatus for constructing a prosthetic limb socket. The method involves the steps of: a) creating a positive cast of a patient's residual limb; b) positioning a mechanical press on a distal end of the positive cast; c) molding a prosthetic socket component over the positive cast and over the mechanical press; and d) activating the mechanical press such that the prosthetic socket component is pushed apart from the distal end of the positive cast. Preferably, the mechanical press includes a spacer component adapted to abut a distal surface of the positive cast, a pusher component adapted to abut a proximate surface of a socket component formed over the positive cast, and an actuator for moving the pusher component from the spacer component. Thus, the method preferably also involves the step of activating the actuator to move the pusher component from the spacer component.

Abstract: A system and method for fabricating a thermoplastic prosthetic limb socket from a thermoplastic preform cone involves the steps of: obtaining a digital or physical positive representation of a patient's residual limb; determining a desired thickness for the thermoplastic socket; selecting a thermoplastic preform cone; calculating the dimensions of a proximate extension to be added to the proximate end of the digital or physical representation of the patient's residual limb based upon the dimensions of the patient's residual limb, the dimensions of the preform cone, and the desired thickness of the thermoplastic socket; forming a positive socket mold based upon the combined dimensions of the patient's residual limb and the extension; heating the preform cone; and stretching the preform cone over the positive cast. Preferably the method is performed on a CAD tool.

Abstract: A system and method for fabricating a cosmetic cover for a prosthetic limb comprises the steps of: fitting and aligning a prosthetic limb to a wearer's residual limb; collecting orientational and positional data from adjustment points between the various endoskeletal and/or socket components of the residual limb; transmitting the orientational data to a CAD system that has access to the socket and endoskeletal component dimensions; using the CAD system to calculate inner surface dimensions for a cosmetic cover to be worn over the prosthetic limb according to the socket and endoskeletal component dimensions and according to the orientational and positional data; and downloading the inner surface dimensions from the CAD system to a CNC milling machine, which is adapted to carve the inner surface of a cosmetic cover from a carving blank using the calculated inner surface dimensions.

Abstract: A system and method for fabricating a thermoplastic prosthetic limb socket from a thermoplastic preform cone involves the steps of: obtaining a digital or physical positive representation of a patient's residual limb; determining a desired thickness for the thermoplastic socket; selecting a thermoplastic preform cone; calculating the dimensions of a proximate extension to be added to the proximate end of the digital or physical representation of the patient's residual limb based upon the dimensions of the patient's residual limb, the dimensions of the preform cone, and the desired thickness of the thermoplastic socket; forming a positive socket mold based upon the combined dimensions of the patient's residual limb and the extension; heating the preform cone; and stretching the preform cone over the positive cast. Preferably the method is performed on a CAD tool.