Prosthetics are artificial limbs produced to replace lost or dysfunctional limbs or organs. These prosthetics are designed to improve the patient's quality of life and restore lost functions. The prosthetic manufacturing process is a complex and personalized process. It generally includes the following steps:
1. Assessment and Measurement
Determining Needs: The first step is to determine the patient's prosthetic needs. At this stage, the doctor and prosthetist determine which limb the patient has lost, what type of prosthesis they need, and which functions they aim to restore.
Measurements and Molds: In order for the prosthesis to be personalized to the individual, detailed measurements are taken of the area where the prosthesis will be applied. If the prosthesis is made for a leg or arm, molds suitable for the shape of the patient's remaining limb are made. These molds are usually obtained with plaster or digital 3D scanning methods.
2. Design Phase
Prosthetic Design: The prosthesis is designed according to the measurements and molds taken. At this stage, the aesthetic appearance of the prosthesis is taken into consideration as much as its functionality. For example, a leg prosthesis is designed to not only help with walking but also to have a natural leg appearance.
Material Selection: The materials used in the production of the prosthesis are selected according to the needs of the patient and the purpose of the prosthesis. Lightness, durability and comfort are the most important criteria. Materials generally used for prostheses:
Carbon fiber: It is preferred especially in leg prostheses because it is durable and lightweight.
Titanium: It is frequently used because it is strong and lightweight.
Silicon: It is used to provide similarity to skin tissue in aesthetic prostheses (for example, hand or face prostheses).
Functional Prostheses: Especially in bionic prostheses (electronically controlled), technologies such as motors, sensors and electronic circuits are added to give the prosthesis the ability to move. Such prostheses are designed in a way that they can be controlled by the user's mind or muscle movements by perceiving nerve signals or muscle movements.
3. Production Process
Mold and Modeling: The molds and design created for the prosthesis are transferred to production. The prosthesis is shaped specifically for the individual. At this stage, depending on the type of material used, the parts of the prosthesis are either molded or produced with 3D printing technologies.
Assembly and Components: After the main structure of the prosthesis is produced, additional parts are assembled. For example, movable joints are added for knee prosthesis, and finger mechanisms are added for hand prosthesis. If the prosthesis is bionic, the integration of electronic components is also done at this stage.
Coating and Finishing Touches: At the end of the prosthesis production process, an outer coating is applied to give the prosthesis a natural appearance. A skin-like appearance is given to the prosthesis using materials such as silicone or latex. In some prostheses, a more realistic appearance is achieved by using special paints that are suitable for the individual's skin color.
4. Prosthesis Application and Testing
Fitting and Fitting: The manufactured prosthesis is fitted to the patient and the first trials are made. At this stage, it is checked whether the prosthesis fits correctly, whether the patient is comfortable, and whether the functions of the prosthesis work smoothly.
Adjustments: If there are problems with the fit or functionality of the prosthesis, adjustments are made to the prosthesis. These adjustments are extremely important for the patient to be able to use the prosthesis comfortably.
Education and Adaptation Process: Especially in functional prostheses (e.g. bionic arms), prosthesis users are taught how to use it. Prostheses controlled by muscle signals may require training for the user to work properly. The user goes through an adaptation process until they get used to the prosthesis.