Evaluation of Biocompatible 3D Printed Prosthetics with Enhanced Functionality for Medical Applications

Abstract

Thermal Advances in additive manufacturing have transformed the development of prosthetic devices, offering rapid customization, lower production costs, and superior adaptability to patient needs. This research evaluates the performance, biocompatibility, and functional enhancement of 3D printed prosthetics produced using medical-grade polymers and composite materials. Experimental assessments were conducted to analyze mechanical strength, surface finish, microbial resistance, and user comfort, while biocompatibility tests examined cytotoxicity, allergenic responses, and tissue interaction behavior. Functionality enhancements—such as embedded sensors, lightweight structural lattices, and adjustable joint mechanisms—were also studied in detail. The results demonstrate that 3D printed prosthetics fabricated from PLA-based composites and thermoplastic polyurethane exhibit strong mechanical resilience and excellent wearer compatibility, while sensor-integrated versions significantly improve adaptability and monitoring. The findings confirm that modern additive manufacturing technologies can produce clinically reliable prosthetics comparable to traditional counterparts, ensuring improved patient mobility and comfort. This study provides important insights into material selection, design optimization, and performance evaluation for next-generation prosthetic development, enabling pathways for medical institutions and manufacturers to adopt advanced 3D printed solutions.