Anderson Orthopedics seeks to improve the production of transtibial sockets for individuals with below-the-knee amputations by addressing inefficiencies in its existing manufacturing processes. This design solution develops a streamlined and sustainable set of standard operating procedures that incorporate digital technologies. This approach reduces production time and hands-on labour, while maintaining high-quality patient care and satisfaction.

The design solution combines Anderson Orthopedics' traditional manual casting method with advanced digital technologies. These technologies include the Vorum Spectra Scanner for 3D scanning and the Canfit computer automated design software for socket modification. To 3D print the sockets, two new programs are introduced in the standard operating procedures for designing. These programs are SolidWorks and SuperSlicer. 3D printing the sockets with two chosen filaments will significantly reduce hands-on labour, eliminate the need for external outsourcing, and reduce production time for both non-weightbearing and weightbearing sockets. Preliminary testing has assessed the design solution’s feasibility through physical property tests (e.g., socket volume retention, diameter retention, subtractive modification), satisfaction surveys, and evaluations of overall manufacturing efficiency. This testing has proven the new process meets Anderson Orthopedics' standards for quality and patient care.

The design solution presented encountered key limitations in 3D printer access, and future recommendations have been provided to improve socket aesthetics, transparency, and structural performance. Addressing these limitations can further improve both the socket quality and the patient experience at Anderson Orthopedics.

The new process reduces hands-on labour time by 22.1% for both the weightbearing and non-weightbearing sockets. Additionally, it decreases overall production time by 6.7% for the weightbearing socket and 26.4% for the non-weightbearing socket. This design solution offers valuable insights into an innovative and efficient prosthetic manufacturing approach for Anderson Orthopedics, reinforcing their commitment to sustainability and excellence.