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 prosthetic limb comprises a socket for receiving a patient's residual limb, and an upright assembly. The socket includes a base provided in its distal end. The base includes a chamber therewithin and an channel for providing fluid communication between the chamber and the interior of the socket. A duct extends through the socket and engages the base such that it is in fluid communication with the chamber. A valve is coupled to the duct to allow controlled or forced gas transfer to and from the interior of the socket. A seal is provided between the base and the socket to facilitate suction between the patient's residual limb and the 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 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 modular interface connector for coupling a prosthetic limb socket assembly to a prosthetic limb upright assembly comprises an interface cushion member adapted to fit substantially entirely within the distal end of the socket, having a proximate end adapted to abut the wearer's residual limb; a first attachment mechanism for releasably attaching the interface connector within the distal end of the socket; and a second attachment mechanism for releasably attaching the upright assembly to the distal end of the socket. When attached in the socket, the interface connector provides an air-tight seal between the attachment mechanism and the wearer's residual limb.

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.

Abstract: A removable interface cushion for a prosthetic limb is adapted to be snugly fitted within a prosthetic limb outer socket over the interconnection components which connect the outer socket to the upright assemblies. The interface cushion is adapted to abut and provide comfort to the wearer's residual limb when the socket is worn on the residual limb, because the interface cushion is formed from an elastomeric material and has a substantially concave proximate surface. The interface cushion also includes a cavity in the distal end of the cushion for receiving the interconnection components; and the mouth of the cavity has an annular projection extending therefrom which is adapted to abut the inner surface of the socket to create an airtight seal between the interface cushion and the inner surface of the socket when the cushion is snugly fitted into the distal end socket cavity.

Abstract: A prosthetic limb comprises a socket for receiving a patient's residual limb, and an upright assembly. The socket includes a base provided in its distal end. The base includes a chamber therewithin and an channel for providing fluid communication between the chamber and the interior of the socket. A duct extends through the socket and engages the base such that it is in fluid communication with the chamber. A valve is coupled to the duct to allow controlled or forced gas transfer to and from the interior of the socket. A seal is provided between the base and the socket to facilitate suction between the patient's residual limb and the socket.

Abstract: A modular interface connector for coupling a prosthetic limb socket assembly to a prosthetic limb upright assembly comprises a base, adapted to fit within the distal end of the socket; and an interface cushion, having a proximate end adapted to abut the wearer's residual limb, mounted on the base. The base includes interconnection components in its distal end such that the modular interface connector can be releasably mounted within the distal end of the socket and such that the upright assembly can be releasably mounted to the distal end of the base and, in turn, to the distal end of the socket. When mounted in the socket, the interface connector provides an air-tight seal between the base and the inner surface of the socket to facilitate a suction fit of the wearer's residual limb in the socket.