Prosthetic limbs comprising three-dimensionally printed elements

Abstract

A prosthetic appendage for attachment to an outer extremity of an amputated limb that is composed of modular elements fabricated by three-dimensional printing. In one embodiment the prosthetic appendage is a leg. The prosthetic leg includes a foot portion and a plurality of modular and three-dimensionally printed limb elements. One of the plurality of limb elements is pivotally coupled to the foot portion and another of the limb elements is configured at one end to receive the outer extremity of the amputated leg. In another embodiment of the present invention the prosthetic appendage is a hand. The prosthetic hand includes a wrist element with one end configured to receive the outer extremity of an amputated hand, a base portion attached to the wrist element and a plurality of modular and three-dimensionally printed finger elements selectively coupled to adjacent finger elements or the base to form prosthetic fingers.

What is claimed is: 
     
         1 . A prosthetic appendage for attachment to an outer extremity of an amputated limb, comprising:
 a base element;   a plurality of three-dimensionally printed modular limb elements forming a protrusion at a first end and forming at a second and opposing end a recess to receive the protrusion from an adjacent three-dimensionally printed limb element;   a first three-dimensionally printed modular limb element having an end pivotally connecting to the base element; and   a second three-dimensionally printed modular limb element having an end configured to receive the outer extremity of the amputated limb instead of engaging an adjacent limb element.   
     
     
         2 . The prosthetic appendage of  claim 1  wherein the base element forms a hand structure. 
     
     
         3 . The prosthetic appendage of  claim 1  wherein the base element forms a foot structure to support walking upon the prosthetic appendage. 
     
     
         4 . The prosthetic appendage of  claim 3  further comprising a prosthetic joint including:
 a sphere; 
 a first three-dimensionally printed joint element forming at a first end a depression configured to receive a portion of the sphere and forming at a second and opposing end a protrusion or a recess to engage another of the plurality of three-dimensionally printed limb elements; and 
 a second three-dimensionally printed joint element forming at a first end a recess to receive a portion of the sphere. 
 
     
     
         5 . The prosthetic appendage of  claim 4  further comprising:
 at least a pair of flexible and non-extensible connectors attached to opposing sides of the first and the second joint elements generally perpendicular to a pivot plane; and 
 at least a pair of flexible and elastically extensible connectors attached to opposing sides of the first and the second joint elements generally parallel to the pivot plane. 
 
     
     
         6 . The prosthetic appendage of  claim 3  further comprising a prosthetic knee structure including:
 a first three-dimensionally printed knee element forming at a first end a ridge and forming at a second and opposing end a protrusion or recess to engage an adjacent one of the plurality of limb elements, the first knee element further defining a plurality of apertures at the first end and in a side of the first knee element, the apertures at the first end communicating with the apertures formed in the side; 
 a second three-dimensionally printed knee element forming at a first end a pair of ridges spaced apart to slidingly receive the ridge of the first knee element and forming at a second and opposing end a protrusion or recess to engage an adjacent one of the plurality of limb elements, wherein the sliding engagement of the ridge of the first knee element between the pair of ridges of the second knee element affords relative motion between the first and second knee elements in generally a single plane, the second knee element further defining a plurality of apertures at the first end and in a side of the second knee element, the apertures at the first end communicating with the apertures formed in the side; 
 a plurality of tensioning elements respectively and detachably attached to the first and second knee elements; 
 a plurality of flexible and non-extensible connectors respectively attached at opposing ends to pairs of the tensioning elements, a first tensioning element of a pair being detachable attached to the first knee element and a second tensioning element of a pair being detachably attached to the second knee element, the flexible and non-extensible connectors being further threaded through the apertures of the first and second knee elements, wherein relative motion of the first and second knee elements is prohibited when the flexible connectors are tensioned by the pair of tensioning elements being attached to the first and second knee elements, and wherein relative motion of the first and second knee elements is permitted when the flexible connectors are slack. 
 
     
     
         7 . The prosthetic appendage of  claim 3  further comprising a prosthetic knee structure including:
 a first three-dimensionally printed knee element forming at a first end a ridge and forming at a second and opposing end a protrusion or recess to engage an adjacent one of the plurality of limb elements, 
 a second three-dimensionally printed knee element forming at a first end a pair of parallel ridges spaced apart to slidingly receive the ridge of the first knee element and further forming at a second and opposing end a protrusion or recess to engage an adjacent one of the plurality of limb element, wherein sliding engagement of the ridge of the first knee element between the pair of ridges of the second knee element affording relative motion between the first and second knee elements in generally a single plane; 
 at least one flexible and elastically extensible connector attached to and disposed internally in each of the first and second knee elements; and 
 a locking element slidingly disposed about the first and second knee elements, wherein the locking element prohibits relative motion between the first and second knee elements when positioned about both the first and second knee elements and permits relative motion between the first and second knee elements when positioned about only one of the first and second knee elements. 
 
     
     
         8 . A prosthetic leg for attachment to an outer extremity of an amputated leg, comprising:
 a foot element;   a plurality of modular and three-dimensionally printed limb elements forming a protrusion at a first end and forming at a second and opposing end a recess configured to receive the protrusion from an adjacent limb element;   at least one of the three-dimensionally printed limb element being pivotally attached to the foot element; and   at least one of the three-dimensionally printed limb element forming at one end a cavity configured to receive the outer extremity of the amputated leg.   
     
     
         9 . The prosthetic leg of  claim 8  further comprising an ankle joint including:
 a sphere; 
 a first three-dimensionally printed ankle element shaped at a first end to receive a portion of the sphere and forming at a second end a protrusion or recess to engage another of the plurality limb elements; and 
 the foot element further including an upper surface shaped at to receive a portion of the sphere. 
 
     
     
         10 . The ankle joint of  claim 9  further comprising:
 at least a pair of non-extensible and flexible connectors attached at first ends to opposing sides of the first ankle element generally perpendicular to a pivot plane, and further attached at second ends to the upper surface of the foot element; and 
 at least a pair of flexible and elastically extensible connectors attached to opposing sides of the first ankle element generally parallel to the pivot plane, and further attached at second ends to the upper surface of the foot element. 
 
     
     
         11 . The prosthetic appendage of  claim 8  further comprising a prosthetic knee structure including:
 a first three-dimensionally printed knee element forming at a first end a ridge and forming at a second and opposing end a protrusion or recess to engage an adjacent one of the plurality of limb elements, the first knee element further defining a plurality of apertures at the first end and in a side of the first knee element, the apertures at the first end communicating with the apertures formed in the side; 
 a second three-dimensionally printed knee element forming at a first end a pair of ridges spaced apart to slidingly receive the ridge of the first knee element and forming at a second and opposing end a protrusion or recess to engage an adjacent one of the plurality of limb elements, wherein the sliding engagement of the ridge of the first knee element between the pair of ridges of the second knee element affords relative motion between the first and second knee elements in generally a single plane, the second knee element further defining a plurality of apertures at the first end and in a side of the second knee element, the apertures at the first end communicating with the apertures formed in the side; 
 a plurality of tensioning elements respectively and detachably attached to the first and second knee elements; 
 a plurality of flexible and non-extensible connectors respectively attached at opposing ends to pairs of the tensioning elements, a first tensioning element of a pair being detachable attached to the first knee element and a second tensioning element of a pair being detachably attached to the second knee element, the flexible and non-extensible connectors being further threaded through the apertures of the first and second knee elements, wherein relative motion of the first and second knee elements is prohibited when the flexible connectors are tensioned by the pair of tensioning elements being attached to the first and second knee elements, and wherein relative motion of the first and second knee elements is permitted when the flexible connectors are slack. 
 
     
     
         12 . The prosthetic appendage of  claim 8  further comprising a prosthetic knee structure including:
 a first three-dimensionally printed knee element forming at a first end a ridge and forming at a second and opposing end a protrusion or recess to engage an adjacent one of the plurality of limb elements, the first knee element further defining a plurality of apertures at the first end and in a side of the first knee element, the apertures at the first end communicating with the apertures formed in the side; 
 a second three-dimensionally printed knee element forming at a first end a pair of ridges spaced apart to slidingly receive the ridge of the first knee element and forming at a second and opposing end a protrusion or recess to engage an adjacent one of the plurality of limb elements, wherein the sliding engagement of the ridge of the first knee element between the pair of ridges of the second knee element affords relative motion between the first and second knee elements in generally a single plane, the second knee element further defining a plurality of apertures at the first end and in a side of the second knee element, the apertures at the first end communicating with the apertures formed in the side; 
 a plurality of tensioning elements respectively and rotatingly coupled to the first and second three-dimensionally printed limb elements; 
 a plurality of flexible and non-extensible connectors respectively attached at opposing ends to pairs of the tensioning elements, a first tensioning element of a pair being detachable attached to the first knee element and a second tensioning element of a pair being detachably attached to the second knee element, the flexible and non-extensible connectors being further threaded through the apertures of the first and second knee elements, wherein relative motion of the first and second knee elements is prohibited when the flexible connectors are tensioned by the pair of tensioning elements being attached to the first and second knee elements, and wherein relative motion of the first and second knee elements is permitted when the flexible connectors are slack. 
 
     
     
         13 . The prosthetic appendage of  claim 8  further comprising a prosthetic knee joint including:
 a sphere; 
 a first three-dimensionally printed knee joint element forming at a first end a depression configured to receive a portion of the sphere and forming at a second and opposing end a protrusion or a recess to engage another of the plurality of three-dimensionally printed limb elements; and 
 a second three-dimensionally printed knee joint element forming at a first end a recess to receive a portion of the sphere. 
 at least a pair of flexible and non-extensible connectors attached to opposing sides of the first and the second joint elements generally perpendicular to a pivot plane; 
 at least a pair of flexible and elastically extensible connectors attached to opposing sides of the first and the second joint elements generally parallel to the pivot plane, and 
 a locking element slidingly disposed about the first and second knee elements, wherein the locking element prohibits relative motion between the first and second knee elements when positioned about both the first and second knee elements and permits relative motion between the first and second knee elements when positioned about only one of the first and second knee elements. 
 
     
     
         14 . A prosthetic hand for attachment to an outer extremity of an amputated hand, comprising:
 a three-dimensionally printed wrist element having one end configured to receive the outer extremity of the amputated hand,   a three-dimensionally printed base element attached at one end to the wrist element;   a first plurality of modular and three-dimensionally printed finger elements each pivotally coupled to an adjacent finger element or the base element, each finger element defining a first aperture extending through the finger element and further defining a pair of apertures on one side of the finger elements at opposing ends of the finger element, at least one of the finger elements further pivotally coupled to the base element;   a first flexible connector having a first portion attached at a first end to the base element and threaded internally through the plurality of finger elements and a second portion exiting a first finger element and entering an adjacent second finger element through adjacent apertures in the sides of the adjacent finger elements;   an actuator mounted on the base and having a mobile element attached to a second end of the first flexible connector wherein activation of the actuator causes displacement of the first flexible connector with respect to the base portion and causes the first plurality of finger elements to pivot with respect to the base portion and with respect to one another thereby opening or closing the first plurality finger elements; and   a controller configured to activate and deactivate the actuator.   
     
     
         15 . The prosthetic hand of  claim 14  further comprising a thumb structure including:
 a second plurality of three dimensionally printed thumb elements, each thumb element defining a first aperture extending through the thumb element and further defining a pair of apertures on one side of the thumb elements at opposing ends of the thumb elements, at least one of the thumb elements further pivotally coupled to the base element to pivot in a plane generally perpendicular to a pivot plane of the first plurality of three-dimensionally printed finger elements; 
 a second flexible connector having a first portion attached at a first end to the base element, threaded internally through the plurality of thumb elements and a second portion exiting a first thumb element and entering an adjacent second thumb element through adjacent apertures in the sides of the adjacent thumb elements and attached at a second end to the actuator wherein activation of the actuator causes displacement of the second flexible connector with respect to the base portion and causes the second plurality of thumb elements to pivot with respect to the palm portion and with respect to one another thereby opening or closing the second plurality thumb elements. 
 
     
     
         16 . The prosthetic hand of  claim 14  wherein the first plurality of three dimensionally printed finger elements each form at a first end a ridge and form at an opposing second end a slot spaced to slidingly receive the ridge of an adjacent three-dimensionally printed finger element, wherein the sliding engagement of the ridge of a first finger element between the slot of an adjacent second three-dimensionally printed finger element affords pivoting between the first and second finger elements. 
     
     
         17 . The prosthetic hand of  claim 14  wherein at least one of the first and second flexible connectors are elastically extensible. 
     
     
         18 . The prosthetic hand of  claim 14  wherein the controller is responsive to signals sent from a smart phone. 
     
     
         19 . The prosthetic hand of  claim 14  wherein sensors communicating with the controller are mounted on at least one of the first plurality of three-dimensionally printed finger elements, and wherein the controller is configured to deactivate the actuator when a signal is received from the sensor.