29 Ravi DP2 ESE Report

WALCHAND COLLEGE OF ENGINEERING,
SANGLI
(An Autonomous Institute)
DEPARTMENT OF MECHANICAL ENGINEERING

A
Dissertation Phase II (ESE) Report on
“Design, Topology Optimization and Analysis of

Prosthetic Foot Made using 3D Printing”
Submitted in partial fulfilment of the requirement of award of degree of
Master of Technology
in
Mechanical Design Engineering
Submitted by
Mr. Ravikiran G Margepwar

(PRN NO: 2019MTEMEDE029)
Under the guidance of
Prof. V. V. Dhende
2020-2021
ABSTRACT
The scope of the work is to design, develop and analysis of Prosthetic foot made by using
additive manufacturing technique, it also deals with the complete design process of a motion
prosthetic foot manufactured by using Poly lactic acid (PLA) material. Along with the
fabrication process we also tried to minimize the weight of prosthetic foot by applying topology
optimization from ANSYS Workbench. The topology optimized model is printed using a
Three-dimensional (3D) printer. In order to validate the structure many elemental analysis and
experiments should be conducted on the structure. Since the weight of the prosthetic directly
affects the mobility of patients, the foot should be optimized to weigh lesser. So, by doing what
is necessary the weight should be reduced while the structure maintained at a high strength.
Keywords: 3D printing, FDM technique, Poly Lactic Acid (PLA), Foot prosthetic, FEA, Topology
optimization,
i
INDEX
ABSTRACT i
INDEX ii
NOMENCLATURE iii
LIST OF FIGURES iv
Chapter 1
INTRODUCTION 1
1.1 Relevance 1
1.2 Natural Gait 3
1.3 Additive Manufacturing 4
1.4 Finite Element Analysis 5
1.5 Problem Definition 6
1.6 Objectives 6
1.7 Work Flow 7
Chapter 2
LITERATURE REVIEW 8
Chapter 3
DESIGN AND DEEVELOPMENT 23
3.1 Different Designs Using CCATIA V5R21 23
3.2 Static Structural Analysis Using ANSYS Workbench 18.1 27
3.3 Topology Optimization Using ANSYS Workbench 18.1 30
WORK PLAN 32
CONCLUSION 33
REFERENCES 34
ii
Nomenclature
FEA Finite Element Analysis

AM Additive Manufacturing
PLA Ploy Lactic Acid
COP Coefficient of Pressure
SACH Solid Ankle-Cushion Heel
SAFE Solid Ankle-Flexible Endoskeleton
CAD Computer-aided design
FDM Fused Deposition Modelling
3D Three-Dimensional
CMs Compliant Mechanisms
ABS Acrylonitrile Butadiene Styrene
iii
List of figures
Fig. Name Page

No. No.
1.1 Flow chart of proposed work 7
2.1 A model of prosthetic foot 8
2.2 The novel geometry of the designed foot prosthesis 11
2.3 The damaged prototype (a, b and c) and the similar simulated critical zones. 11
2.4 Gait Cycle 13
2.5 Model of foot 14
2.6 Diagram of A FDM Device 16
2.7 Diagram of A Stress-Strain Curve 16
3.1 Model 1 23
3.2 Model 2 24
3.3 Model 3 24
3.4 Model 4 25
3.5 Model 5 25
3.6 Model 6 26
3.7 Detailed Views of Model 6 26
3.8 Model 1: Static Structural, Equivalent Stress 27
3.9 Model 1: Static Structural, Directional Deformation 27
3.16 Model 1 Topology Optimization, Topology Density Tracker 30
iv
Design, Topology Optimization and Analysis of Prosthetic Foot Made using Additive Manufacturing
Chapter 1
INTRODUCTION
This chapter introduces to reasons for the use of prosthetics and applications of 3D
printed prosthetics in day to day use for general population. Also, in this chapter we
discussed natural gait cycle of humans, a bit about additive manufacturing especially
Fused Deposition Modelling (FDM) and Finite Element Analysis (FEM) procedures.
Similarly, the relevance, problem definition, objectives and workflow of the
dissertation work are stated in this chapter.
1.1 Relevance
Feet form the basis of our body and our movement. Healthy feet are essential for comfort,
mobility and balance. Providing contact to the ground, the foot provides shock absorption and
stability during stance. Additionally, it influences gait biomechanics by its shape and stiffness.
This is because the trajectory of the centre of pressure (COP) and the angle of the ground
reaction forces is determined by the shape and stiffness of the foot and needs to match the
subject's build in order to produce a normal gait pattern. So, it is obvious that any injury or ill
effect to it makes big impact on a persons’ day to day activities.
The word ‘prosthesis’ comes via New Latin from the Greek ‘prostithenai’ meaning ‘to add to,
or to put in addition.’ The plural of prosthesis is prostheses. A prosthesis or prosthetic implant
is an artificial device that replaces a missing body part, which may be lost through trauma,
disease, or a condition present at birth (congenital disorder). Prostheses are intended to restore
the normal functions of the missing body part. Due to increased foot loss due to accident and
increased foot amputation rate due to malignancy or gangrene, the demand for new prosthetic
foot is also present widely. People who are affected by such events expect the technology to
serve them at most. To overcome these difficulties prosthetics are being developed which are
relatively available at low cost and more accessible than bionic i.e., biomechanical components
present in development phase.
Most commercially available foot prostheses are passive. Their materials are either carbon or
glass fiber reinforced composites, which are able to store and return a sufficient amount of
energy to provide propulsion. The rapid development of additive manufacturing techniques
Walchand College of Engineering, Sangli. 1

makes it possible to design 3D-printable foot prostheses that have the properties of passive feet.
Its geometric freedom makes it possible to maximize strength and minimize weight.
Topology optimization is used to make design even better with same characteristics. Topology
optimization is a phrase used to characterize design optimization formulations that allow for
the prediction of the lay-out of a structural and mechanical system. That is, the topology or
“landscape” of the structure should be an outcome of the procedure. In principle the result of a
topology optimization procedure is also optimal with respect to size and shape, but it is here
essential to note that fundamental differences in the design parameterization means that direct
comparisons are difficult in practice. Moreover, topology optimization is often restricted to
design situations with a moderate number of constraints. One should always consider topology
optimization as a companion discipline that provides the user with new types of designs that
may be processed directly or which may be further refined using size and shape optimization
[1].
Topology optimization is an approach that determines the best material distribution in a given
design domain that can minimize a given cost function while satisfying a series of constraints.
Recently developed topology optimization methods are strongly related to finite element
analysis. In topology optimization, the design domain is modelled using finite elements. The
material property (e.g., Young’s modulus or cross-sectional dimensions) of each finite element
is controlled. If the material in a certain region needs to be removed, then the corresponding
material property will approach zero. Methods that use link/beam elements to discretize the
candidate design domain are classified as discretization topology optimization methods.
The most representative method in discretization topology optimization is the ground structure
approach. The primary work on synthesizing the topology of CMs using the ground structure
method was presented in, where the flexibility and the stiffness were considered simultaneously
by using a weighted sum. Since then, abundant studies have focused on the optimizing the
topology of CMs using the ground structure approach.
Topology optimization that is performed based on continuum discretization (e.g., bilinear

quadrilateral element) is classified as continuum topology optimization.
The commercially available foot is made up of glass fibre reinforced composites or light
weighted metal matrix composites. These are designed to redirect a sufficient amount of energy

to provide forward propulsive force for motion. By using the development of additive
manufacturing technique, it is possible to design a 3D-printable foot that possess the properties
of commercial passive foot.
The FDM (Fused Deposit Modelling) technology is being adopted for printing purpose. Its
geometric freedom makes it possible to maximize strength and minimize weight. The
geometric freedom provides the customization to meet the varying requirements of patients.
The PLA (Poly Lactic Acid) material filament plastic with good mechanical properties is used
for fabrication purpose. Overall, we can ease out the majority amputees with prosthetics using
these techniques with reduced costs [2].
1.2 Natural Gait

While walking may seem simplistic to those with two healthy lower limbs, this does not imply
that the act of ambulation is without complexity. When walking, individuals subconsciously
use many different control algorithms and compensatory mechanisms in order to walk
efficiently. Even after decades of research, many of the control patterns applied during
ambulation remain superficially understood. Further adding to the complexity of the problem,
gait patterns vary significantly for each individual. However, one identical aspect is
minimization of the metabolic cost of walking.
To gain an understanding of the importance of the novel ankle prosthesis presented here, one
must have a basic understanding of the gait cycle and its associated nomenclature and
terminology. Much of the terminology used in the gait analysis
Gait Cycle: The gait cycle starts when one foot makes contact with the ground and ends when
the same foot contacts the ground again. The cycle can be broken down into various phases
and periods to determine normal and pathological gait.
Sagittal Plane: A sagittal plane is any plane which divides the body into right and left portions.
For the ankle in normal gait, the bulk of motion and loading occurs in this plane.
Dorsiflexion: Dorsiflexion is defined as the rotation of the top of the foot towards the shin and
can also be defined by the orientation of the foot relative to the leg where the angle between
the two is less than 90°.

Plantarflexion: Plantarflexion is rotation of the top of the foot away from the shin and can
also be defined by the orientation of the foot relative to the leg where the angle between the
two is greater than 90°.
Inversion/Eversion Rotation about the ankle joint that occurs in the frontal plane (plane that
divides the body into front and back), with inversion being an inward rotation, and eversion
being an outward rotation.
Stance/Swing Phase: The stance phase is the portion of one gait cycle in which the foot is in
contact with the ground. Conversely, the swing phase is the period in which the foot is not in
contact with the ground.
Single/Double Support: Describes how many of an individual’s feet are in contact with the
ground at an instance in time.[3]
1.3 Additive Manufacturing
Additive Manufacturing refers to a process by which digital 3D design data is used to build up
a component in layers by depositing material. The term "3D printing" is increasingly used as a
synonym for Additive Manufacturing. However, the latter is more accurate in that it describes
a professional production technique which is clearly distinguished from conventional methods
of material removal. Instead of milling a work piece from solid block, for example, Additive
Manufacturing builds up components layer by layer using materials which are available in fine
powder form. A range of different metals, plastics and composite materials may be used.
The technology has especially been applied in conjunction with Rapid Prototyping - the
construction of illustrative and functional prototypes. Additive Manufacturing is now being
used increasingly in Series Production. It gives Original Equipment Manufacturers (OEMs) in
the most varied sectors of industry the opportunity to create a distinctive profile for themselves
based on new customer benefits, cost-saving potential and the ability to meet sustainability
goals.
Additive manufacturing uses data computer-aided-design (CAD) software or 3D object

scanners to direct hardware to deposit material, layer upon layer, in precise geometric shapes.

As its name implies, additive manufacturing adds material to create an object. By contrast,
when you create an object by traditional means, it is often necessary to remove material through
milling, machining, carving, shaping or other means.
Although the terms "3D printing" and "rapid prototyping" are casually used to discuss additive
manufacturing, each process is actually a subset of additive manufacturing. While additive
manufacturing seems new to many, it has actually been around for several decades. In the right
applications, additive manufacturing delivers a perfect trisect of improved performance,
complex geometries and simplified fabrication. As a result, opportunities abound for those who
actively embrace additive manufacturing.
Traditionally, prosthetic and orthotic materials commonly used were wood, leather, and fabric.
Fabrication technology has increased over the past several decades to increase this materials
list. Now prosthetic and orthotic devices can be made using preimpregnated carbon fiber,
rubber, steel, aluminium, titanium, thermoplastics, and thermosets.
The main appeal of FDM, aside from the resolution of the device, is the wide selection of
materials available that can be printed simultaneously and fused together during fabrication
that do not require post-production modification. Therefore, a rubberlike material can be used
adjacently and even fused to a rigid material to supply a combination of support and cushion.
Currently, FDM printers have the ability to use over 140 materials with unique material
properties.
The FDM (Fused Deposition Modeling) technology has a number of benefits. The geometric
freedom of the additive technology makes it possible to maximize strength and minimize
weight. The geometric freedom provided by 3D printing helps customize prostheses to meet
the varying needs of patients. The CAD models are adjustable after testing with amputees,
based on their feedback. Using this method an optimal geometry can be created for low-volume
production or for individual custom prosthetic. The PLA filament plastic with good mechanical
properties is used for fabrication purpose.
1.4 Finite Element Analysis

Finite element analysis is a computational tool that allows for displacement and stresses to be
calculated for a complex shape. This technique creates a finite element, or mesh where the
individual elements can vary in size and shape. An FEA model contains information regarding

the complex shape’s geometry, material properties assigned to the shape, magnitude and
direction of forces being applied to the shape, and constraints or fixtures of the complex shape.
This information is needed to determine the displacement and stresses that occur when external
forces are applied to the complex shape. The nodes of the elements found within the mesh
represent the corners of the finite elements. Each of these nodes in a structural problem exhibits
6 degrees of freedom, translations in three directions and rotations about these three directions.
Most nodes in the mesh are unconstrained, with the fixtures of the shape being the only
elements that are constrained. These fixtures are known as the boundary conditions. The finite
element analysis software then solves for all of the unknown nodes. A three-dimensional finite
element consists of at least four nodes which do not lie in the same plane. The three possible
finite elements in a three-dimensional analysis are the tetrahedron, pentahedron, and
hexahedron. When hundreds or thousands of these finite elements are required to represent
complex shapes, hundreds or thousands of unknowns and equations are created. Computer
finite element software arranges these unknowns and equations into a matrix, and perform the
iterative process of solving for the unknowns to determine the displacements at every node in
the complex shape.
1.5 Problem definition

In prosthetic industry, additive manufacturing is still a new dawn and a lot of research is going
on in biomechanics, wearable devices, advance prosthetic limbs, bionics etc. This is an attempt
to design a lite-weight prosthetic foot for low to medium level amputees using additive
manufacturing technique.
Designing, analyzing and developing a topology optimized foot prosthetic for amputees which
will be easy to manufacture and cost effective; designed by using CAD software, analyzed by
Finite Element method, topology optimized by best suited method and made with the help of
additive manufacturing for reduction in weight of the component and the cost.
1.6 Objectives
The objectives of the study are,
1. To design a prosthetic foot using CAD software

2. To optimize the topology of designed model
3. To analyze the designed foot using Finite element method.
4. To develop the optimized model using additive manufacturing process and test for
strength.

1.7 Workflow
Literature Review
CAD Design Based on

the study
Static Structural Analysis of

CAD model using ANSYS
Topology Optimization using

ANSYS
Interpretations from the study

and analysis of the results
Conclusion of the Study
Report Writing and

Presentation
Fig 1.1: Flow chart of proposed work
Thus, in this chapter we gave complete outline of the project with small introduction to each
ideas and work to do in the project ahead. Along with showing the desired Work-Plan for the
project.

Chapter 2
LITERATURE REVIEW
The literature review on Design and Development of Prosthetic foot is carried out and
found how previous researchers studied in this area and their approach about finding
the best suited foot prosthesis for the amputees. Papers on Topology Optimization,
Additive Manufacturing techniques and amputation related health issues were also
studied during this review. The research papers reviewed are cited from book and
journals such as Elsevier, Science Direct, Springer, Discovery.
V. Vijayan et al. [4] in their work on design and analysis of Prosthetic foot using additive
manufacturing technique they have delt with the complete design process of a motion prosthetic
foot manufactured by using Poly Lactic Acid (PLA) material.
Fig. 2.1 A model of prosthetic foot [4]
They were able to reduce the weight of foot fabricated that earlier available models. The outlay
of their portable prosthetic foot is designed and optimized by weight as light as possible by
using optimization of topology technique. Finally, the topology optimized model is printed by
using a Three-dimensional (3D) printer.
In order to validate the structure many elemental analysis and experiments are conducted in the
structure. Since the weight of the prosthetic directly affects the mobility of patients, the foot is
optimized to weigh 0.23 kg (230 g). By using topology optimization technique, the weight is
drastically reduced while the structure is maintained at a high strength.

Numerous prosthetic leg designs are available with various materials and functions. Although
prosthetic foot is popular, the standard design is not established yet. This is due to the dedicated
function. Passive foot is simple in design and does not have any moving parts. The design of
prosthetic foot is for walking purpose. Bionic feet are becoming popular as they adopt bio-
mechanical integrated knowledge and principles. In this review, the optimum approach to
analyze the performance of prosthetic foot is discussed. The objective of this study was to
reduce the weight of the foot without any deviations in the structural and mechanical
performance of foot. Even though, many materials like poly lactic acid, acrylonitrile butadiene
styrene (ABS), and nylon 6 are used for fabrication using fused deposition modelling (FDM)
and conventional injection moulding, this foot is fabricated completely by using PLA material
because of its strength and stiffness than ABS and also seems to be readily and cheaply
available.
Material: (Polylactic acid) PLA
• Biodegradable Polymer, Soluble in chlorinated solvents, hot benzene, dioxane
etc.
Material Properties
Youngs’ Modulus 3.54 𝐺𝑃𝑎
Poisons Ratio 0.33
Density 0.01054
𝑘𝑔
𝑚𝑚
Tensile yield strength 60.4 𝑀𝑃𝑎
Compressive yield Strength 23 𝑀𝑃𝑎
Tensile Ultimate Strength 35 𝑀𝑃𝑎
Compressive ultimate Strength 2600 − 13600 𝑃𝑆𝐼
Melting Temperature 173 − 178℃
A number of CAD models were designed, all adjustments of the model were followed by FEA,
thus optimizing its strength. The split forefoot and the heel provide a 2-point support. The front
support points are positioned according to the human foot. The heel is robust just like the
human heel. The rear rib had to be implemented due to high stress at the heel area; moreover,
the heel was of same width as front end in order to increase the area that is in contact with the

ground. The CAD adjustments aimed to create a low-build prosthesis so that it would fit lower
amputees as well. The prototype was made for a 216 mm long foot with a height of 82 mm and
width of 70 mm. It corresponds to a human foot.
The FEA was conducted in each and every support phases of the walking cycle. In every phase,
the critical position of the ankle was considered. Moreover, the average maximum lateral load
and the auxiliary torque (the load line is not aligned with the axis of the mounting pyramid)
were superimposed on the vertical load (weight). Matching the prototype’s size, a person with
90 kg body mass was presumed for the FEA. The vertical load of the model was 1.5 times the
person’s weight (900 N). The lateral load was defined as 23% of the body weight that is 207
N. The auxiliary torque was calculated at 15,750 Nm for a 900 N vertical load. As far as the
mechanical properties are concerned, the tensile strength and modulus of the PLA were used
in the simulation. The material model was defined as linear and isotropic. The material
properties and the geometry of the model are more ardent, which helps to mesh the solid
structure for elemental analysis.
By using this study, the complete design and analysis process of a portable prosthetic foot is
done. The structure of this prosthetic foot is designed and optimized as light as possible by
using topology optimization. The topology-optimized model is printed from a Three-
dimensional (3D) printer. The finite element analysis is conducted to validate the structure.
Thus, the cost of the foot drastically reduces when it undergoes batch or mass production
process.
Bence Rochlitz et al. [2] in their study found that, recent developments in additive
manufacturing methods enable to create individual prostheses, using scanned data or
parametric models. Therefore, it is worth investigating the possibilities and limitations of such
products. The requirements of prosthetic feet are difficult to comply with and differ in
evaluation aspects such as rollover shape, energy return, load-bearing capability, etc.
This paper presents simulation methods conducted on self-designed prosthetic foot concepts.
One design was manufactured using Fused Deposition Modelling and ABS filament. The effect
of the geometry and infill pattern on the energy return is discussed based on test results. The
load-bearing capability of the initial design was improved due to its failure, and examined by
more extensive simulations.

Fig 2.2: The novel geometry of the designed foot prosthesis [2]
Conclusion from the literature:

In conclusion, the 3D-printable prosthetic foot design presented in this paper shows that such
products built of ABS filament have a potential to be a low-cost solution for moderate activity
level amputees. Based on the data collected during quasi-static testing, the energy return of the
prosthesis is sufficient (88.0 ± 5.1%). For high activity level patients, new CFF technology will
enable to 3D-print ESAR feet with greater strength.
Fig 2.3: The damaged prototype (a, b and c) and the similar simulated critical zones.[2]
The development of a novel 3D printed prosthesis is limited to the materials and not to the
design of the prosthesis. Seeing the evolution of 3d printing materials, with time more and
better materials can be chosen to print a functional end-user product.

Kalyan Chakravarthy et al. [5] in their paper presents the components of knee joint which
supports the individuals with above knee amputations. The objective of this paper is to design
and analyze a pliant prosthetic knee joint and find possibilities and necessary measures to suit
the requisites of a refine substitute of a comfortable and light weight prosthetic knee joint. One
of the main challenges related with the advancement of prosthetic knee joint components for
amputee individuals with above-knee amputations associates with the requirement to design
light-weight structures which are proficient of withstanding the high loads that are usually
present during mobility. This work deals with the dimensions of the knee which are taken from
able-bodied individuals. The modelling of the knee is done with the help of solid works and
the model is analyzed using Altair Hyper works software. The 3D model has been generated
using Solid works modelling software. The Finite Element meshing is done using Altair Hyper
mesh and the meshed component was solved using optistruct. A proto type of knee is examined
for structural fortitude of lower-limb prosthesis.
When a prosthetic leg has to be manufactured its design should be according to the patient’s
physical appearance and functional needs, it is important for the amputees to select correct
mechanical knee that fits their needs. There are categories within the mechanical prosthetic
knees. They all have distinct features that correlate with a wearer’s age, health, activity level
and life style. The knee we opt for must provide a reliable support when standing, allow smooth
controlled motion when walking and permit unrestricted movement for sitting, bending,
kneeling. Fit and alignment are the basic considerations for designing of a prosthetic leg.
Gait analysis:
Gait is described as a person’s way, style or manner of movement or locomotion. Speed of gait
decides the involvement of all body segments. Ordinary walking speed mainly involves the
lower extremities, by means of the arms and the trunk by providing equilibrium and stability.
When there is a faster speed, the body depends more on the upper extremities and the trunk for
balance and stability. The limbs persist to do the work as the joints generate great ranges of
motion trough greater muscle response. The three main joints of lower body and pelvis in
bipedal system work by means of each other, since muscles and momentum make the body
move forward. The centre of the body moves side to side and up and down throughout gait.
The gait cycle is shown in the Figure below.

Fig 2.4: Gait Cycle [5]
Mechanism compliances:
Mechanical systems corresponding to compliant mechanisms employ’s a flexible or elements
with large-displacement, which opposes the utilization of the elements which are exceptionally
inflexible and stiff. The mechanisms which are in use are almost traditional and are commonly
used in the manufacturing field at present are called rigid-body mechanisms. They engage solid
linkages joined by joints which permit relative motion linking them. Compliant equal in values
of such mechanisms are replaced by the linkages and joints by means of a particular portion of
material having rigid and flexible parts. The compliant mechanisms are relatively a recent study
in design and research field, but it is one which has increase in its significance due its potential
utilization and benefits over the mechanisms of rigid-body. The property of the flexible part
returning to its actual position after being released is a resilient advantage. These mechanisms
are generally lighter in weight and of low expenditure than the rigid-body mechanisms without
any change in strength. Since these mechanisms are regularly built in a single piece, the
modelling techniques and manufacturing is greatly simplified. Even in the absence of rigid-
body links, where the parts of machine persistently come in contact against each other, there is
decrease in wear significantly.
This paper mainly includes the virtual prototyping of a prosthetic leg including the socket. 3D
modelling was done using solidworks software and was carried out in hypermesh. Analysis
was carried out for different materials which were easily available in the market and the results
for these materials were shown in the graphs. Based on the results obtained boron epoxy has
high strength and exhibits lesser deflections but it is not easily available in the market so
aluminium considered as the best alternative for prosthetic leg material which was easily
available and also shows low number of deflections.

Fig 2.5: Model of foot [5]
It can be concluded that the proposed virtual model is very much suitable as a prosthetic leg
replacement since maximum stresses occurs at very low values. This design can further be
optimized by using several bio compatibility materials and eco-friendly materials like coconut
fibres etc. This design also can be optimized for lesser material usage.
Benjamin Joseph Cahill [6] in his paper discussed following aspects of the additive
manufacturing techniques and foot prosthesis related issues as follows:
Fused Deposition Modelling (FDM) technology was utilized to fabricate the prosthetic devices
that were designed and put through a Finite Element Analysis to simulate static loading and
fatigue testing during various stages of the gait cycle.
For humans, the foot, spacer, and securement system are manufactured independently by
prosthetic companies. The socket and assembly of the prosthetic leg system is performed by a
Certified Prosthetist (CP) at a privately owned clinic or a prosthetic device company. Multiple
designs are available for the prosthetic foot depending on the expected activity level of the end
user. These designs include the solid ankle-cushion heel (SACH), solid ankle-flexible
endoskeleton (SAFE), single-axis foot, multi-axis foot, and dynamic-response foot. The Solid
Ankle Cushioned Heel (SACH) foot consists of a rigid keel, and a rubber heel. The density of
the rubber heel is selected based on the weight of the end user. Mechanically, the SACH foot
is completely static. The SACH foot, SAFE foot, single-axis foot, and multi-axis foot are used

by individuals desiring to achieve moderate activity levels. To accommodate individuals with

a desire for even higher levels of activity, the dynamic-response foot was designed.
The design and material used for this type of foot stores energy during heel strike and returns
stored energy to the user during push-off. This energy is stored in the elastic properties of the
material used, and returns the energy when the material returns to its natural conformation. The
dynamic-response foot provides a more normal range of motion and a balanced gait as
compared to a multi-axis foot.
To help increase stability of the foot during increased activity, most dynamic-response feet
have a split toe design. The split toe feature enables the toes to apply a uniform force to an
uneven surface without rotating the heel. This is particularly critical when ambulating over
rough or uneven terrain, such as sand or grass. further reduces the size of the “dead spot” so
that most individuals experience a smooth motion from heel strike to push-off. This design is
currently the closest biomechanical representation of a natural foot.
Fused Deposition Modelling (FDM):

It is the basis of 3-D printing. FDM resembles a traditional inkjet printer, but instead of ink,
the device uses a thin filament of plastic. The printer head then melts the filament and extrudes
it onto the build plate. Similar to STL, the printer head, like the UV laser, moves in the x-y axis
while the build plate travels along the z axis. The resolution of this technique depends on the
thickness of the filament but is typically 0.25 mm. The lower resolution also requires hand
sanding the surface to post-process. The FDM printing process requires the use of a support
material printed along with the actual build material that washes away in a water bath.
Therefore, no chemicals are required post-process. The machine and material of this technique
are relatively inexpensive; The printing heads used in FDM have become more complex which
enables multiple materials to be used simultaneously without requiring changing of filament
material or additional time.
Materials:
Materials selection for prosthetic and orthotic devices has traditionally focused on 6
characteristics including yield strength, stiffness, durability, density, corrosion resistance, and
ease of fabrication. Yield strength refers to the maximum stress a material can withstand before
permanent deformation occurs, which is very important in a load-bearing prosthetic device.

Fig 2.6: Diagram of A FDM Device.[10]
Not only does the device need to withstand the individual’s bodyweight, but also the increased
forces during walking, running, and jumping. Another characteristic related to strength is the
stiffness of the material. Stiffness refers to the stress-to-strain (or Young’s Modulus) ratio. A
material will stretch or compress a certain distance whenever a force is applied. The ultimate
strain of a material refers to the amount of bending deformation, compression, or elongation a
material exhibits before failure.
The compressive stress applied to a material refers to the applied load that acts to reduce the
length of the material in along the axis through which it was applied. Shear stress refers to the
stress state resulting from the combined energy of opposing forces acting along parallel lines
of action. Tensile stress refers to the stress state resulting from applied loads that elongate the
material along the axis through which the force is applied.
Fig 2.7: Diagram of A Stress-Strain Curve [10]

Figure (2.7) above represents the stress-strain plot for a plastic material. In order to have a fully
supporting prosthetic device, a high-stiffness material is desired. However, a high-stiffness
material may reduce the amount of flexibility and comfort the socket provides the individual.
The device needs to provide sufficient stiffness to withstand day to day activities, yet be
comfortable enough so that the individual chooses to use the device. The relationship between
stiffness and comfort comes from the material or materials used, and the design of the prosthetic
device and socket.
The durability of the device refers to the ability of the selected materials to withstand repeated
force loading and unloading while maintaining material integrity. Many materials degrade or
become fatigued after repeated exposure to loading and unloading. Once a material is fatigued,
the force required to reach failure is reduced. Since a prosthetic device is loaded and unloaded
with every step, repeated hundreds to thousands of times per day, fatigue strength is an
important material characteristic in prosthetics.
The density, or mass per unit of volume, is a concern for all prosthetic users because a low
density reduces the overall device weight. Decreasing the weight of the prosthetic system or
increasing the device’s energy storage and return minimizes the metabolic energy required to
ambulate, allowing increased mobility. Corrosion resistance and ease of fabrication are
important characteristics pertaining to the life cycle and fabrication of the device. Additional
characteristics to consider are material costs and availability. Consideration of all of these
characteristics guides material selection.
Another measure of a materials ability to withstand a load is the factor of safety. Factor of
safety is a ratio used in structural applications to determine the ratio of the maximum working
stress to the maximum stress the material can withstand. The factor of safety for components
that are to be subjected to repeated impact loading, as expected in a cat jumping from a height,
should be no less than 10. The final design is the product of numerous designs and testing
iterations until a finalized product with a sufficient life expectancy is created.
Tuan D. Ngo et al. [7] in their paper discussed about Freedom of design, mass customisation,
waste minimisation and the ability to manufacture complex structures, as well as fast
prototyping, are the main benefits of additive manufacturing (AM) or 3D printing. A
comprehensive review of the main 3D printing methods, materials and their development in

trending applications was carried out. In particular, the revolutionary applications of AM in

biomedical, aerospace, buildings and protective structures were discussed. The current state of
materials development, including metal alloys, polymer composites, ceramics and concrete,
was presented. In addition, this paper discussed the main processing challenges with void
formation, anisotropic behaviour, the limitation of computer design and layer-by-layer
appearance. Overall, this paper gives an overview of 3D printing, including a survey on its
benefits and drawbacks as a benchmark for future research and development.
3-D printing is an additive manufacturing (AM) technique for fabricating a wide range of
structures and complex geometries from three-dimensional (3D) model data. The process
consists of printing successive layers of materials that are formed on top of each other. This
technology has been developed by Charles Hull in 1986 in a process known as
stereolithography (SLA), which was followed by subsequent developments such as powder
bed fusion, fused deposition modelling (FDM), inkjet printing and contour crafting (CC). 3D-
printing, which involves various methods, materials and equipment, has evolved over the years
and has the ability to transform manufacturing and logistics processes. Additive manufacturing
has been widely applied in different industries, including construction, prototyping and
biomechanical. The uptake of 3D printing in the construction industry, in particular, was very
slow and limited despite the advantages e.g., less waste, freedom of design and automation.
AM is able to 3D print small quantities of customised products with relatively low costs. This
is specifically useful in the biomedical field, whereby unique patient-customised products are
typically required. This technology has gained the attention of those in the medical field, due
to its ability to produce a wide variety of medical implants from CT-imaged tissue replicas.
One of the main drawbacks of 3D printing is void formation between subsequent layers of
materials. The additional porosity created by AM can be very high and can thereby reduce
mechanical performance due to the reduction of interfacial bonding between printed layers.
The extent of void formation highly depends on the 3D printing method and the printed
material. In the methods that use filaments of materials such as FDM or contour crafting, the
formation of voids is more common and considered as one of the main defects that result in
inferior and anisotropic mechanical properties. This void formation can also result in
delamination between layers after printing. In a 3D printed composite using the FDM method,
increasing the thickness of the filament decreased the porosity but deteriorated cohesion in the

composite, which resulted in a reduction of tensile strength and an increase in water uptake.
The increased thickness of concrete layers with more time lapse between subsequent layers
resulted in better interlayer bonding and less void formation in the additive manufacturing of
concrete. On the other hand, in the powder-bed printing of alumina/glass composite, the high
porosity of AM can be reduced substantially by minimising the height of each layer. The
reduced height can increase laser penetration through the top layer and promote diffusion of
ceramic powders between layers, thereby reducing interlayer void formation.
The higher porosity of 3D printed parts is not always a defect and can be exploited in
applications for which controlled porosity is considered as an advantage of AM e.g., porous
scaffold design in tissue engineering. Minas et al. took advantage of void formation due to the
3D printing process. They introduced larger pores into a lattice structure on top of micro-pores,
which were created by air bubbles inside the foam filament. For bio composites, the higher
porosity of the 3D printed part can introduce hygroscopic properties by increasing the ability
to retain water.
However, the anisotropic behaviour of 3D-printed materials can be helpful in some

applications. For instance, the special anisotropic wettability of a surface can be achieved by
controlling the properties of 3D printed filaments (e.g., speed and spacing) on the surface. A
super-hydrophobic and anisotropic 3D-printed polydimethylsiloxane film with excellent
thermal durability for applications such as breathable water-repellent surfaces has been
developed.
Computer-aided design (CAD) software is the main tool to design a part that can be 3D printed.
Because of limitations in AM, the printed part can have a few defects that were not expected
in the designed element. The CAD system is a combination of solid geometry and boundaries.
It typically employs tessellation concepts to approximate the model. However, transferring
CAD into a 3D-printed part often results in inaccuracies and defects particularly in curved
surfaces. A very fine tessellation can potentially resolve this problem to some extent but the
computed processing and printing will be time-consuming and complicated. Therefore, post-
processing (by heat, laser, chemicals or sanding) to eliminate these defects are sometimes
considered.

To limit divergence from design to execution, it is necessary to plan and find the optimum
orientation of the part, slice the part into sufficient layers and generate supporting materials,
which must support the addition of subsequent layers and can easily be removed after printing.
The powder-bed method has the advantage of using unbound powder as the support, which can
easily be removed by air pressure after printing. On the other hand, FDM, counter crafting and
inject printing need to create external support, which is not always easy to remove.
Conclusions drawn from the paper can be written as follows:

Freedom of design, mass-customisation and the ability to print complex structures with
minimum waste are the main benefits of 3D printing. A comprehensive review of 3D printing
methods, materials and the current state in trending applications in various industries was
carried out. The main challenges that are attributed to the nature of 3D printing were also
discussed.
In terms of methods, fused deposition modelling (FDM) is one of the most common 3D printing
technologies because of low-cost, simplicity and high-speed processing. It is originally used
for D printing of polymer filaments but has been adapted to many other materials. FDM is
mainly used for fast prototyping, and the mechanical properties and quality of the printed parts
are lower compared to the powder-bed methods such as selective laser sintering (SLS) and
selective laser melting (SLM). Adjacent powders are fused, melted or bonded together by using
an auxiliary adhesive in Powder-bed methods, which result in finer resolutions but incur higher
costs and are slower processes. Direct energy deposition (DED) uses a source of energy (laser
or electron beam) to melt metal powders but no powder bed is used compared to SLM and the
feedstock is melted before deposition in a layer-by-layer fashion similar to FDM but with an
extremely higher amount of energy for melting metals.
The reinforcement of polymers with fibres and nano-materials resulted in enhancing the
mechanical properties of the 3D printed composite to be used as a functional material. Despite
the benefits of additive manufacturing, there are a few drawbacks that would require further
research and development to adopt this technology in various industries. Void formation
between subsequent layers of materials results in additional porosity during the manufacturing
process, which can reduce mechanical performance due to a reduction in interfacial bonding
between printed layers.

Anisotropic behaviour is another common challenge of AM, which results in different

mechanical behaviour under vertical tension or compression compared to that of the horizontal
direction. Also, transferring CAD into a 3D-printed part often results in inaccuracies and
defects, especially in curved surfaces due to the tessellation concept of CAD, which is an
approximation of the design. Moreover, the layer-by-layer appearance of AM in applications
such as buildings, toys and aerospace are not preferable. Ongoing research and development
of materials and methods have helped to circumvent some of these challenges but there is still
room for improvement.
Despite being a revolutionary method for customised products and niche applications, 3D
printing needs more development in order to compete with traditional methods in the mass
production of ordinary goods because of its higher cost and lower speed. Nonetheless, the
evolution of AM in recent years has been phenomenal. The increased funding, research and
development worldwide would result in a fast transition from traditional methods of
manufacturing to 3D printing in the near future.
Ole Sigmund [8] in their paper presented a method for optimal design of compliant mechanism
topologies. The method is based on continuum-type topology optimization techniques and
finds the optimal compliant mechanism topology within a given design domain and a given
position and direction of input and output forces. By constraining the allowed displacement at
the input port, it is possible to control the maximum stress level in the compliant mechanism.
The ability of the design method to find a mechanism with complex output behaviour is
demonstrated by several examples.
In this paper, the concept and methods of using continuum-type topology optimization for the
design of compliant mechanisms if presented. It is demonstrated that the maximum stress in a
compliant mechanism can be controlled by introducing a displacement constraint at the input
port. It is shown that the optimal compliant mechanism topology is highly dependent on the
work task considered.
In the literature, compliant mechanisms have been categorized as distributed. Or lumped

compliant mechanisms, Subject to an input load, fully compliant mechanisms bend throughout
the structure, whereas lumped compliant mechanisms bend in flexural hinges. This paper
shows that both distributed and lumped compliant mechanisms can be optimal, depending on

the work-task considered. Finally, some of the mechanisms obtained by the design procedure
are built and tested, both in macroscale (made of Nylon) and in microscale (made of glass).
The conclusion from this paper is drawn as follows:
The examples presented show that the proposed method for optimal design of compliant
mechanisms indeed can be used as an efficient tool for compliant mechanism synthesis.
Although the method could be used as a design tool as is, much work still must be done to fully
understand and optimize the behaviour of compliant mechanisms. The first extension needed
is to implement direct stress constraints in the formulation. This extension will slow
computational speed, but it will also result in different and improved optimum mechanism
topologies. Other important extensions are the detailed modelling of flexural hinges, extensions
to large displacements, and variable supports.
Ignoring stress constraints, the present method's ability to predict mechanism topologies and
locate optimum positions of hinges can probably be used as an alternative method for optimal
synthesis of rigid body mechanisms. A further extension of the mechanism design procedure
is to allow for two (or more) materials. If two materials have different properties-for example,
two different thermal expansion coefficients-or one is passive and the other is active
(piezoelectric, shape memory alloy, etc.), it will be possible to design devices that can be
activated using, for example, heat or electric fields. A three-phase (two materials and void)
topology optimization method for the design of material structures with extreme (also negative)
thermal expansion coefficients has been suggested by Sigmund and Torquate. This work can
be used as a basis for the design of active compliant mechanisms that are composed of multiple
materials.

Chapter 3
DESIGN AND DEVELOPMENT
In Design and Development phase of the prosthetic foot at this stage a number of
CAD Models were drawn in CATIA and their adjustments and structural analysis
were followed by FEA using ANSYS, to increase the ground area contact heel was
kept of same width as of Front end of designed foot in some cases. Topology
optimization of few of the models is done to check feasible options for further
reduction and developments in the designed models
3.1 Different Designs of Foot

In this phase we developed a model based on previously known models and the work up
forth by previous researchers. In development of the CAD Model a number of different models
have been drawn and designed based on the measurement of human foot and the data also
collected by measuring feet.
All adjustments of the model were followed by FEA, thus optimizing its strength. The split
forefoot and the heel provide a 2-point support. The front support points are positioned
according to the human foot.
Fig 3.1 Model 1

Here Fig. (3.1) can be seen as first prototype made by assuming a completely solid model with
appropriate size of human right foot.

The heel is robust just like the human heel. The rear rib had to be implemented due to high
stress at the heel area; moreover, the heel was of same width as front end in order to increase
the area that is in contact with the ground.
Fig 3.2 Model 2

Made a hollow model 2 as shown in Fig (3.2) from model 1 to start the drawing process with
changes in first model by taking trial and error method in consideration.
Fig 3.3 Model 3

Added few supports to model 2 to check whether it would be enough to support the load and if
it can withstand the weight in structural analysis. Thus Model 3 (Fig 3.3) is formed from the
idea of model 2 (Fig 3.2).
In Model 3 (Fig 3.3) the upper-level structure where load is to be applied seemed to have less
strength and was vulnerable to more deformation and buckle down was prominent in that
structure after extra load was applied so it was given more support by adding an arch just below

the structure to increase strength and give a better structural integrity to the model as well. Thus
model 4 (Fig 3.4) was formed from previous model.
Fig 3.4 Model 4
Fig 3.5 Model 5
In first solid structure drawn the model is completely solid so having maximum material used
and it would be heavy for the amputee to use for lite work applications and day to day use for
low level activities as well, then changes were followed on the models to make preferred model
for 3D printing.
Here model 5 (Fig. 3.5) was developed in such a way to counter the effects of loads on the
dome shaped structure of model 4 (Fig. 3.4). We changed that model to accommodate the stress

strain results found out by doing ANSYS Calculations. Few of these ANSYS results were
shown in figures below.
Fig 3.6 Model 6
Fig 3.7 Detailed View of Model 6
Model Dimensions: Model I: L = 265 mm H = 90 mm

Other Models: L = 250 mm H = 80 mm width = 75 mm

3.2 Static Structural Analysis

The static structural analysis of the model showing equivalent (Von-Mises) Stress results from
the downward loading applied on them.
Fig 3.8 Model 1: Static Structural, Equivalent Stress
Fig 3.9 Model 1: Static Structural, Directional Deformation
The Static Structural Analysis of few models is shown here to show the results of the stress and
deformation analysis the models have been through.

Here in most of these models we can see the maximum stress is taking place at position where
the load is applied and small number of deflections are observed here and there in the structure.

If the deflection is more and would it harm the structure, we added some support to the structure
making it robust for such scenarios.

3.3 Topology Optimization

Here in Ansys Workbench 18.1 we got topology optimization of the structure option and while
trying out the feature found that this shows material can be removed which is not necessary for
keeping the strength intact while performing the same task. So, we checked this for some of
our designs and found out how to improve them at some extent.
Fig 3.16 Model 1 Topology Optimization, Topology Density Tracker

In this way we studied various models and analysed their structure using ANSYS Software and
it will help to choose further modifications and necesaary changes to the model we will finalize
on the way for production using additive manufacturing.

Work Plan:
Work Aug Sept Oct Nov Dec Jan Feb Mar Apr May Jun Jul
Activity 20 20 20 20 20 21 21 21 21 21 21 21
Topic
Identification
Literature
Review
Designing
few models in
CAD
Topology
Optimization
Techniques
Analyzing
using FEM
Developing
prototype: 3D
printing
Finding the
results and
comparison
Draft
preparation
Report
writing and
submissions
Activity Planned
Activity Completed

Conclusion:
These are few work-related results and conclusions we have reached at from this study till now:
 Prosthetics based on amputee needs are different from person to person and it is easier
to fabricate them using additive manufacturing techniques.
 Developed six different CAD models based on medium sized right foot of human adult
male.
 Using trial and error method conducted finite element analysis on some of the models
to check their strength and directional deformation using ANSYS Workbench 18.1
 Applied toplology optimization on some of the models to check material removal from
them to find approach to actual working model.

REFERENCES
[1] Martin P Bendose, Ole Sigmund, “Topology Optimization” in: Jasbir S. Arora,
Optimization of Structural and Mechanical Systems, World Scientific Publishing Company,
Singapore, 2007, 161.
[2] Bence Rochlitz, David Pammer, Design and Analysis of 3D Printable Foot Prosthesis,
Periodica Polytechnica Mechanical Engineering,61(4), pp. 282-287, 2017
https://doi.org/10.3311/PPme.1108
[3] Alexander J. Folz’ Design of a Passive Ankle Prosthesis with Energy Return That Increases
with Increasing Walking Velocity’, Master's Theses (2009 - 2010). 448.
[4] V. Vijayan, S. Arun Kumar, S. Gautham et al., Design and analysis of prosthetic foot using
additive manufacturing technique, Materials Today: Proceedings,
https://doi.org/10.1016/j.matpr.2020.07.195
[5] Kalyana Chakravarthy, Pavan Kishore, Ashok, Manoj, Mithun Chakravarty, Srinath (2015)’
Virtual prototyping and analysis of a robotic prosthetic leg’, 46(213), October 1, 2015
[6] Benjamin Joseph Cahill (2016) ’Development and evaluation of custom prosthetic devices
for a companion animal utilizing additive manufacturing.’ 7-2016.
[7] Tuan D. Ngo, Alireza Kashani, Gabriele Imbalzano, Kate T.Q. Nguyen, David Hui (2018)’
Additive manufacturing (3D printing): A review of materials, methods, applications and
challenges’, Composites Part B 143 (2018) 172–196.
[8] Ole Sigmund (1997) On the Design of Compliant Mechanisms Using Topology Optimization,
Mechanics of Structures and Machines, 25:4, 493-524
http://dx.doi.org/10.1080/08905459708945415

Dissertation Phase II ESE Report
Mr. Ravikiran Govindrao Margepwar

PRN No. 2019MTEMEDE029
M.Tech (Mechanical Design Engineering)
Walchand College of Engineering
Sangli-416 415
Prof. V.V. Dhende Prof. A.S. Bhandare

(Guide) (External Examiner, DEC) (Chairman, DEC)
Prof. Dr. K. H. Inamdar

Head of Department
Department of Mechanical Engineering
Walchand College of Engineering
Sangli-416 145

29 Ravi DP2 ESE Report

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WALCHAND COLLEGE OF ENGINEERING,

DEPARTMENT OF MECHANICAL ENGINEERING

Dissertation Phase II (ESE) Report on

“Design, Topology Optimization and Analysis of

Mr. Ravikiran G Margepwar

Under the guidance of

FEA Finite Element Analysis

Fig. Name Page

Walchand College of Engineering, Sangli. 1

Topology optimization that is performed based on continuum discretization (e.g., bilinear

Walchand College of Engineering, Sangli. 2

1.2 Natural Gait

Walchand College of Engineering, Sangli. 3

1.3 Additive Manufacturing

Additive manufacturing uses data computer-aided-design (CAD) software or 3D object

Walchand College of Engineering, Sangli. 4

1.4 Finite Element Analysis

Walchand College of Engineering, Sangli. 5

1.5 Problem definition

1. To design a prosthetic foot using CAD software

Walchand College of Engineering, Sangli. 6

CAD Design Based on

Static Structural Analysis of

Topology Optimization using

Interpretations from the study

Conclusion of the Study

Report Writing and

Fig 1.1: Flow chart of proposed work

Walchand College of Engineering, Sangli. 7

Fig. 2.1 A model of prosthetic foot [4]

Walchand College of Engineering, Sangli. 8

Youngs’ Modulus 3.54 𝐺𝑃𝑎

Poisons Ratio 0.33

Tensile yield strength 60.4 𝑀𝑃𝑎

Compressive yield Strength 23 𝑀𝑃𝑎

Tensile Ultimate Strength 35 𝑀𝑃𝑎

Compressive ultimate Strength 2600 − 13600 𝑃𝑆𝐼

Melting Temperature 173 − 178℃

Walchand College of Engineering, Sangli. 9

Walchand College of Engineering, Sangli. 10

Conclusion from the literature:

Walchand College of Engineering, Sangli. 11

Walchand College of Engineering, Sangli. 12

Fig 2.4: Gait Cycle [5]

Walchand College of Engineering, Sangli. 13

Fig 2.5: Model of foot [5]

Walchand College of Engineering, Sangli. 14

by individuals desiring to achieve moderate activity levels. To accommodate individuals with

Fused Deposition Modelling (FDM):

Walchand College of Engineering, Sangli. 15

Fig 2.6: Diagram of A FDM Device.[10]

Fig 2.7: Diagram of A Stress-Strain Curve [10]

Walchand College of Engineering, Sangli. 16

Walchand College of Engineering, Sangli. 17

trending applications was carried out. In particular, the revolutionary applications of AM in

Walchand College of Engineering, Sangli. 18

However, the anisotropic behaviour of 3D-printed materials can be helpful in some

Walchand College of Engineering, Sangli. 19

Conclusions drawn from the paper can be written as follows:

Walchand College of Engineering, Sangli. 20

Anisotropic behaviour is another common challenge of AM, which results in different

In the literature, compliant mechanisms have been categorized as distributed. Or lumped

Walchand College of Engineering, Sangli. 21

Walchand College of Engineering, Sangli. 22