A Review of Lightweight Research on 3D Printed Prosthetic Structure Based on Topology Optimization

Authors

  • Kangdi Zhong School of Aeronautics, Changji University; Xinjiang Key Laboratory of Intelligent Control and Safety Assurance Technology for Low-Altitude Airspace; Key Laboratory of Aircraft Design, Manufacture and Maintenance
  • Lian Xue School of Aeronautics, Changji University; Xinjiang Key Laboratory of Intelligent Control and Safety Assurance Technology for Low-Altitude Airspace
  • Wen Sun School of Aeronautics, Changji University; Xinjiang Key Laboratory of Intelligent Control and Safety Assurance Technology for Low-Altitude Airspace
  • Haoyu Wang School of Aeronautics, Changji University

DOI:

https://doi.org/10.62177/jaet.v3i2.1289

Keywords:

Topology Optimization, 3D Printing, Prosthetic Limbs, Lightweight Structure

Abstract

The lightweight of prosthetic limb is the key to improve the wearing comfort and user experience. The integration of topology optimization and 3D printing technology provides a new path for it. This paper reviews the application status, key technologies and existing problems of topology optimization and 3D printing in the field of lightweight prosthetic limbs. The research shows that the integration of topology optimization and 3D printing is an important direction for the lightweight and customization of prostheses. At present, there is still room for improvement in algorithm adaptation and process coordination. In the future, it is necessary to promote the landing of technology through multidisciplinary cross-disciplinary to provide better rehabilitation aids for the disabled.

Downloads

Download data is not yet available.

References

Eschenauer, H. A., Olhoff, N. (2001). Topology optimization of continuum structures: A review. Applied Mechanics Reviews, 544(4): 331-390. 10.1115/1.1388075

Garner, E., Kolken, H. M. A., Wang, C. C. L. et al. (2019). Compatibility in microstructural optimization for additive manufacturing. Additive Manufacturing, 26: 65-75. 10.1016/j.addma.2018.12.007

Gretsch, K. F., Lather, H. D., Peddada, K. V. et al. (2016). Development of novel 3D-printed robotic prosthetic for transradial amputees. Prosthetics & Orthotics International, 403(3): 400-403. 10.1177/0309364615579317

Vijayavenkataraman, S., Fuh, J., Lu, W. (2017). 3D Printing and 3D Bioprinting in Pediatrics. Bioengineering, 43(3): 63. 10.3390/bioengineering4030063

Chua, C. K., Leong, K. F., 3D Printing and additive manufacturing: Principles and applications (with companion media pack)-of rapid prototyping. World Scientific Publishing Company; 2014.

Vogiatzis, P., Chen, S., Wang, X. et al. (2017). Topology optimization of multi-material negative Poisson’s ratio metamaterials using a reconciled level set method. Computer Aided Design, 83: 15-32. 10.1016/j.cad.2016.09.009

Gao, J., Xue, H., Gao, L. et al. (2019). Topology optimization for auxetic metamaterials based on isogeometric analysis. Computer Methods in Applied Mechanics and Engineering, 352: 211-236. 10.1016/j.cma.2019.04.021

Zhang, G., Khandelwal, K. (2019). Computational design of finite strain auxetic metamaterials via topology optimization and nonlinear homogenization. Computer Methods in Applied Mechanics and Engineering, 356: 490-527. 10.1016/j.cma.2019.07.027

Zhou, H., Zhao, M., Ma, Z. et al. (2020). Sheet and network based functionally graded lattice structures manufactured by selective laser melting: Design, mechanical properties, and simulation. International Journal of Mechanical Sciences, 175: 105480. 10.1016/j.ijmecsci.2020.105480

Chen, Y., Ye, L., Xu, C. et al. (2021). Multi-material topology optimisation of micro-composites with reduced stress concentration for optimal functional performance. Materials & Design, 210: 110098. 10.1016/j.matdes.2021.110098

Ma, W., Lu, Y., Wang, P. et al. (2023). Double Optimization Design of the Formula Racing Car Frame Based on the Variable Density Method and the Joint Variable Method. Applied Sciences, 1318(18): 10155. 10.3390/app131810155

Lestari, W. D., Adyono, N., Faizin, A. K. et al. (2024). Optimization of 3D printed parameters for socket prosthetic manufacturing using the taguchi method and response surface methodology. Results in Engineering, 21: 101847. 10.1016/j.rineng.2024.101847

You, W. S., Casebier, J., Mandich, J. et al. (2021). Genetic Algorithm-Based Optimization for the Geometric Design of a Novel Orthopedic Implant. Ieee Transactions On Bio-Medical Engineering, 6812(12): 3620-3627. 10.1109/TBME.2021.3080226

Muslim, K., Shafira, A., Kurnianto, R. R. et al. (2025). Enhancing Above-Knee Prosthetic Design for Inclusive Workplaces: Ergonomic Considerations in Manual Material Handling. Jurnal Optimasi Sistem Industri, 241(1): 102-120. 10.25077/josi.v24.n1.p102-120.2025

Raszewski, Z., Chojnacka, K., Kulbacka, J. et al. (2023). Mechanical Properties and Biocompatibility of 3D Printing Acrylic Material with Bioactive Components. Journal of Functional Biomaterials, 141(1): 13. 10.3390/jfb14010013

Hemmerling, M., Nether, U. (2014). Generico: A case study on performance-based design. Design Proceedings, 18(8): 126-129. 10.5151/despro-sigradi2014-0021

Lestari, W. D. L., Ariadi, Y., Putra, A. (2026). Customized Prosthetic Feet via Topology Optimization and 3D Printing: A Critical Review. Advanced Mechanical and Mechatronic Systems, 21(1): 33-49. 10.53623/amms.v2i1.776

Liu, X., Yue, Y., Wang, C. et al. (2022). Topology Optimization Method for Calcaneal Prosthesis. Journal of Shanghai Jiaotong University (Science), 272(2): 240-249. 10.1007/s12204-021-2324-2

Tang, Z., Yao, X., Feng, W. (2022). Design Exploration of 3D Printed Prosthesis for Children from an Embodied Perspective. Chinese Art, 5(5): 47-53.

Yang, Y., Song, X., Li, X. et al. (2018). Recent Progress in Biomimetic Additive Manufacturing Technology: From Materials to Functional Structures. Advanced Materials, 3036(36): 1706539. 10.1002/adma.201706539

Salazar, M., Portero, P., Zambrano, M. et al. (2025). Review of Robotic Prostheses Manufactured with 3D Printing: Advances, Challenges, and Future Perspectives. Applied Sciences, 153(3): 1350. 10.3390/app15031350

Compton, B. G., Lewis, J. A. (2014). 3D‐Printing of Lightweight Cellular Composites. Advanced Materials, 2634(34): 5930-5935. 10.1002/adma.201401804

Jin, Z., He, C., Fu, J. et al. (2022). Balancing the customization and standardization: exploration and layout surrounding the regulation of the growing field of 3D-printed medical devices in China. Bio-Design and Manufacturing, 53(3): 580-606. 10.1007/s42242-022-00187-2

Li, C., Wu, C., Lin, C. (2020). Design of a patient-specific mandible reconstruction implant with dental prosthesis for metal 3D printing using integrated weighted topology optimization and finite element analysis. Journal of the Mechanical Behavior of Biomedical Materials, 105: 103700. 10.1016/j.jmbbm.2020.103700

Zhu, J., Hu, J., Zhu, K. et al. (2023). Design of 3D-printed prostheses for reconstruction of periacetabular bone tumors using topology optimization. Frontiers in Bioengineering and Biotechnology, 11: 1289363. 10.3389/fbioe.2023.1289363

Prost, V., Johnson, W. B., Kent, J. A. et al. (2022). Biomechanical evaluation over level ground walking of user-specific prosthetic feet designed using the lower leg trajectory error framework. Scientific Reports, 121(1): 5306. 10.1038/s41598-022-09114-y

Rai, P., Jankiraman, V., Teacher, M. et al. (2022). Design and optimization of a 3D printed prosthetic socket for transtibial amputees. Materials Today: Proceedings, 70: 454-464. 10.1016/j.matpr.2022.09.365

Downloads

How to Cite

Zhong, K., Xue, L., Sun, W., & Wang, H. (2026). A Review of Lightweight Research on 3D Printed Prosthetic Structure Based on Topology Optimization. Journal of Advances in Engineering and Technology, 3(2). https://doi.org/10.62177/jaet.v3i2.1289

Issue

Section

Articles

DATE

Received: 2026-04-12
Accepted: 2026-04-15
Published: 2026-04-20

Most read articles by the same author(s)