Stiffness-driven design and optimization of a 3D-printed composite prosthetic foot: A beam finite Element-Based framework

Composite foot prostheses are traditionally produced via lamination, a process that grants high structural efficiency. However, it is an expensive and time-consuming process. Production rate and customizability are thus limited. Additive manufacturing of composites can be a potential solution to these limitations. This work presents a tool to design and optimize Continuous Fiber-Reinforced Additively Manufactured (CFRAM) prosthetic feet using beam Finite Element (FE) modeling. This optimization tool was developed for weight minimization and obtaining a CFRAM prosthesis design matching up to three static stiffness parameters. The design variables were defined through parametrizing the geometry of the prosthesis designed and using the composite structure parameters. Thanks to the versatility of the tool, solutions to multiple optimization and design cases were used to assess different design concepts, such as the shape of the prosthesis (C-shape or J-shape). Also, the tool successfully duplicated the stiffness characteristics of an assumed laminated prosthesis. Finally, the sources of inaccuracy associated with the beam FE modeling approach were identified through a comparison with plane stress FE analysis.