Translation. Region: Russian Federal
Source: Novosibirsk State University –
An important disclaimer is at the bottom of this article.
Novosibirsk State University is developing lightweight, aesthetically pleasing, and functional cosmetic overlays for leg and thigh prostheses. The project received 1 million rubles in funding from the federal Student Startup competition.
The idea for the project came about in research group of biomechanics and medical engineering(headed by Vladimir Sergeevich Serdyukov), which is based at the Mathematical Center in Akademgorodok and Institute of Medicine and Medical Technologies of NSU is engaged in the development of new solutions and technologies, including digital ones, in the field of limb prosthetics and rehabilitation of amputees.
"By working with rehabilitation centers, we discovered that people with amputations want to disguise the medical appearance of their prosthetics, and existing solutions don't fully address this need—they're either too expensive, offer a limited selection of designs, or are difficult to access in Russia," said Yegor Nikolenko, a third-year student at the Faculty of Mechanics and Mathematics (FMM) and laboratory assistant at the NSU Institute of Mechanics and Mathematics (IMMT), describing the project's origins.
Currently, 3D printing is typically used to manufacture overlays. The key technological advantage of the solution proposed at NSU is its use of polyurethane casting in molds with a relief. This technology allows for faster and more cost-effective production compared to 3D printing, which positively impacts the final cost of the product. Polyurethane also offers other important advantages: it is affordable, wear-resistant, hypoallergenic, and lightweight.
Another important point: most manufacturers of similar polyurethane foam pads only offer options in a standard nude color scheme. These are designed to follow the anatomical contours of the shin and mimic the natural appearance of the leg. Colored options are also available, but they are typically made of plastic.
Work on the project began at the end of last academic year. The team currently consists of four people: third-year students at the Faculty of Mathematics and Mechanics of NSU, Yegor Nikolenko, Sofia Valieva, and Tatyana Shashkina, and a master's student at the Faculty of Mathematics and Mechanics of NSU, Danil Tishchenko. Material samples have already been purchased for strength and wear resistance testing, and work has begun on the technical concept and design of the models. The team is also actively testing materials, practicing the technology for attaching the onlay to the prosthesis, and mastering 3D modeling software.
The technological process for manufacturing onlays includes the following steps: creating a 3D model with a unique relief; producing a prototype mold on a 3D printer; casting liquid polyurethane into the mold with pigment of the desired color; polymerization; and developing a universal attachment system for the prosthesis. This simple and easily scalable technology allows for quick and cost-effective design changes.
"Our product solves two main problems. Firstly, aesthetics and psychology—visually disguising the mechanical structure and, most importantly, providing the user with a tool for self-expression through the choice of designs and colors. This reduces stigma and increases psychological comfort, allowing the prosthesis to be perceived as part of personal style rather than a medical device. This is relevant given the growing demand for customization and improving the quality of life for people with prosthetics. Secondly, it addresses functionality, meaning protecting the expensive prosthesis from external influences," added Yegor Nikolenko.
Within a year, the project will result in the creation of full-size prototypes that have been tested by patients at the Novosibirsk branch of the Moscow Prosthetic and Orthopaedic Enterprise and the Orthos Scientific and Educational Center. The developers hope that their product will be in demand both by end users—people with lower leg or femur amputations—and by orthopedic and prosthetic clinics and rehabilitation centers.
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