How are prosthetics made?

Learn about how prosthetics are made, from the design phase all the way through to follow-up consultations. Gain insights into each step, from capturing the best fit to selecting personalised components, to help you navigate the journey of the creation of a prosthetic leg that enhances your mobility.

Creating a prosthetic leg

The kind of prosthetic leg you may wear will depend on a world of factors, including where you live and what kind of resources you have access to. In this article, we will look at the process of creating a prosthetic leg through a clinical lens, to give you a sense of what happens from the design phase through to follow-up consultations long after your leg has become a natural part of life.

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As unique as you are

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Look to the whole leg, not just one part

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Mechanical and bionic

Your unique prosthetic prescription

Your prosthetic prescription is a detailed description of all the features of your completed prosthetic leg. It usually includes the following:

  • Socket design
  • Skin-socket interface
  • Suspension strategy
  • Additional modular components

Below we will go into a bit more detail about some of these features.

Your socket

The socket must be as comfortable as possible. It provides the basis of the control and comfort with good suspension to your prosthetic leg. The socket is where the prosthetic leg is attached to your residual limb, so the shape must be perfect. The first thing your prosthetist will do is capture the shape of your residual limb to make sure you get this perfect fit.

Capturing the shape of your residual limb

There are various ways of capturing the shape of the residual limb. These include casting directly with an air pressure system and using digital scanners. The most common method is to apply plaster of paris to get a cast of the limb. Plaster of paris is applied to get an impression of the shape of the limb and removed minutes later. Any plaster left behind can easily be removed with water.

Fitting your socket

Using the shape taken from the cast, your prosthetist will often manufacture a diagnostic or ‘test’ socket to evaluate whether the shape will fit comfortably onto your residual limb. The diagnostic socket is typically fitted at the following appointment, as it takes time for the socket to be manufactured, modified and perfected before the final socket is made. The test socket is made from a transparent plastic material and is adjustable.

At Össur, we provide alternative socket technologies such as Direct Socket and Connect TF. Learn more about Össur sockets here.

Putting together the components

Once you and your prosthetist are satisfied with the design and the comfort of the fit, your components will be assembled and aligned with you in a standing position. This process is called ‘static alignment’.

In the fitting process, your prosthetist will try to get the best result, keeping in mind:

  • Your socket should have snug and comfortable fit to best handle your prosthetic leg control and function.
  • Your silicone liner should give you security and reliability, comfort and control.
  • Your knee should give you stability, safety and support, a smooth and symmetric movement.
  • Your foot should provide a safe and stable platform, giving you a natural walking action while protecting you from shock and rotational forces.
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Choosing the look of your new leg

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The moment of truth

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Changing residual limb shape, changing socket