Design, 3D Printing, and Clinical Evaluation of Customized Prosthetic Devices with Enhanced Biocompatibility

Abstract

The Conventional prosthetic devices are often limited by standardized designs that fail to accommodate individual anatomical variation, leading to discomfort, suboptimal functionality, and reduced patient compliance. Recent advances in additive manufacturing and digital biomedical engineering offer unprecedented opportunities to develop customized prosthetic devices tailored to patient-specific requirements. This study presents the design, fabrication, biomechanical assessment, and clinical evaluation of customized prosthetic devices produced using three-dimensional printing technologies. Patient-specific anatomical data were acquired through medical imaging and processed using computer-aided design tools to generate optimized prosthetic geometries. Biocompatible polymeric materials were employed to ensure safety and comfort during prolonged use. Mechanical testing and finite element analysis were conducted to evaluate structural integrity and load distribution. Clinical evaluation involved functional assessment, user comfort analysis, and short-term rehabilitation outcomes. Results demonstrate that customized 3D-printed prosthetics provide superior fit, improved biomechanical performance, and enhanced patient satisfaction compared to conventional devices. The study highlights the transformative potential of additive manufacturing in advancing personalized prosthetic care and rehabilitation engineering.