Digital fabrication and biomechanical optimization of silicone prostheses for partial foot amputation

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Karatoprak A. P., AYDIN L., AKSU B.

Scientific Reports, vol.16, no.1, 2026 (SCI-Expanded, Scopus)

  • Publication Type: Article / Article
  • Volume: 16 Issue: 1
  • Publication Date: 2026
  • Doi Number: 10.1038/s41598-026-47460-3
  • Journal Name: Scientific Reports
  • Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus, BIOSIS, Chemical Abstracts Core, EMBASE, MEDLINE, Directory of Open Access Journals, Zoological Record, Academic Search Ultimate (EBSCO), Natural Science Collection (ProQuest), Biological Science Database (ProQuest), Biomedical Reference Collection: Corporate Edition (EBSCO), Health Research Premium Collection (ProQuest)
  • Keywords: 3D printing, 3D scanning, Digital fabrication, Modern molding, Silicone foot prosthesis, Spacer
  • Open Archive Collection: AVESIS Open Access Collection
  • Kocaeli University Affiliated: Yes

Abstract

Partial foot amputations (PFAs) from diabetes cause major biomechanical deficits. A digital workflow for a patient-specific silicone prosthesis was developed, integrating 3D scanning, CAD with an ulcer off-loading cavity, and multi-part mold fabrication via MSLA 3D printing. Controlled casting with medical-grade silicone (Shore A 30.2) used a novel spacer to ensure a uniform 3 mm wall thickness. Dynamic gait analysis demonstrated that the prosthesis substantially improved load distribution. Maximum plantar pressure was reduced by 36.8%, from 3523.8 g/cm2 to 2225.1 g/cm2, closely matching the healthy foot value of 2245.2 g/cm2. The prosthesis normalized pressure patterns, increasing the medial midfoot contact area from 0.25 cm2 to 2.75 cm2 to promote stability, and the integrated cavity successfully created a pressure relief zone at the ulcer site. Material characterization confirmed the silicone’s targeted compliance (Shore A 30.2) and high elasticity. This end-to-end digital pipeline produced a custom prosthesis that restored near-physiological loading, provided targeted ulcer off-loading, and improved midfoot stability. The methodology offers a reproducible, accurate, and clinically effective alternative to traditional fabrication, with promising implications for improving mobility and wound management in diabetic PFA patients.