Parametric Design of Custom Prosthetic Limbs Covers Using 3D Body Scanning and Algorithmic Modeling for Additive Manufacturing - 25.28

Title:

Parametric Design of Custom Prosthetic Limbs Covers Using 3D Body Scanning and Algorithmic Modeling for Additive Manufacturing

Authors:

Mohammad Saeid HOSEINI 1, Khahsyar HOJJATI EMAMI 1, Mahdi MALEKKHOUYAN 2

1 Industrial Design Department, University of Art, Tehran, Iran;
2 Najaf Abad Azad University, Isfahan, Iran

Keywords:

Prosthetic Limbs, 3D Scanning, Additive Manufacturing, Generative Modeling, Personalization

Abstract:

Prosthetic limbs personalization has been revolutionized by the development of digital fabrication and computational design; yet, aesthetic features of prosthetic limbs are still mostly neglected. Based on an analysis of anatomical scanning accuracy and algorithmic modeling techniques, this article presents a complete generative design workflow for custom limb prosthetic covers. Captured 3D high-resolution surface data is imported into Rhinoceros where Grasshopper scripts create adaptive shell geometries guided by curvature, ventilation, pattern density, and symbolic motifs. A user-friendly interface enables individuals to incorporate cultural and personal preferences from decorative patterns to functional perforations supporting an iterative and collaborative design process. The digital models are tuned for several additive manufacturing techniques and materials to guarantee compatibility across prototyping methods. To validate the workflow, a series of functional prototypes were fabricated and evaluated through user centered testing. Usability testing was conducted with one participant using a lower limb prosthetic, who engaged in the design customization process and provided feedback through structured interviews and a Likert scale survey. Results indicated increased user satisfaction, perceived identity alignment, and a greater willingness to wear the device in social settings. Qualitative feedback emphasized the emotional value of symbolic motifs and lightweight ventilation features. By merging technical precision with expressive customization, this framework establishes a new paradigm for human centered, aesthetically enriched prosthetic solutions.

Full paper:

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Note:

This paper is currently under review for publication in the 3DBDOY.TECH Journal - Vol. 2, 2025 (jrnl.3dbody.tech).
It will be updated also in this page once the review process is concluded.

Presentation:

How to Cite (MLA):

M.S. Hoseini et al., "Parametric Design of Custom Prosthetic Limbs Covers Using 3D Body Scanning and Algorithmic Modeling for Additive Manufacturing", Proceedings of 3DBODY.TECH 2025 - 16th International Conference and Expo on 3D/4D Body Scanning, Data and Processing Technologies, Lugano, Switzerland, 21-22 Oct. 2025, #28, https://doi.org/10.15221/25.28

Details:

Proceedings: 3DBODY.TECH 2025, 21-22 Oct. 2025, Lugano, Switzerland
Paper/Presentation: #28
DOI: https://doi.org/10.15221/25.28

License/Copyright notice

Proceedings: © Hometrica Consulting - Dr. Nicola D'Apuzzo, Switzerland, hometrica.ch.
Authors retain all rights to individual papers, which are licensed under a Creative Commons Attribution 4.0 International License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited.
The papers appearing in the proceedings reflect the author's opinions. Their inclusion in the proceedings does not necessary constitute endorsement by the editor or by the publisher.

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