Multi-objective optimization of prosthetic multi-cells foam liner

Restoring mobility using prosthetic limbs anchored in custom sockets is the primary goal of amputee rehabilitation. The contact pressure at the stump-liner interface is critical for improving prosthetic socket design and enhancing amputee satisfaction and comfort. This study aimed to develop and optimize a new customized multicellular foam liner model by identifying the optimal configuration of the liner's cells to achieve minimal contact pressure between the transtibial limb (stump) and the prosthetic interface while simultaneously minimizing the stump's immersion in the foam liner. The study employed a multi-objective optimization using the NSGA-II genetic algorithm to optimize the material configurations of the liner cells. The objective function was based on a finite element (FE) model of the customized foam liner, composed of 40 cells, each using one of six foam materials with varying firmness. The optimization process yielded nine different configurations representing the Pareto front. Contact pressure and immersion, represented by displacement in the load direction, were reduced from 140 KPa and 9 mm to 10 KPa and less than 1 mm, respectively. The results obtained in this study motivate future clinical trials on the efficacy of customized multicellular foam liners. These findings provide in-depth insights into prosthesis design and customization, potentially leading to further development in the use of foam rather than silicone for liner manufacturing.