The common manufacturing process of prosthetic sockets is usually a time- and labor consuming activity. This project’s purpose was to look for alternative manufacturing methods that could speed up the process and enhance the experience for the patient for example make some personal design or make the socket lighter. The main goal was to investigate which properties could be achieved by applying Electron Beam Melting as an alternative manufacturing process for prosthetic sockets by applying an earlier developed methodology. An investigation of earlier scientific works with the keywords (additive manufacturing, free form fabrication, orthopedic, prosthetic sockets and rapid manufacturing) was done as well as gathering knowledge how to operate and handle the machines necessary to carry out the project. An updated version of the methodology was developed where the design was verified using finite element analysis. With the updated version the methodology contained nine steps, which in short was as follows. First apprehend an inner socket from an orthopedic clinic with a pattern drawn up on it, the pattern is then transferred to a computer environment and manipulated to the desired shape and thickness. A compressive strength test, both virtual and experimental, was designed by a modified version of the ISO-10328 standard and the virtual design was verified before the socket was manufactured in the Electron Beam Melting machine. The manufactured socket was tested in the experimental set-up to verify the virtual one. The result was a personal designed socket of Ti6Al4V including the male pyramid for connection and a suspension system, which consisted of an inner socket and a one-way valve. It was concluded that Electron Beam Melting could be used as an alternative manufacturing process of prosthetic sockets.

The thesis deals with the design of a transtibial prosthesis by additive manufacturing technology. Based on walking biomechanics and the current situation of knowledge a prosthetic foot has been designed for a patient with low level of physical activity. Furthermore, the thesis describes the design of an individual socket for the patient. The socket has been designed by reverse engineer procedure based on the three-dimensional geometry of patient´s stump obtained by 3D scanning. Testing samples of the foot and the socket have been made for the check of functionality of both the devices and then subjected to mechanical tests in accordance to the methodology regulation ISO 10328. Finally, the thesis depicts the FDM technology used for the production of functional samples of the designed devices; assembly of modular transtibial prosthesis and its testing by the patient.