Manufacturing Technology 2025, 25(6):778-787 | DOI: 10.21062/mft.2025.085

Innovative Design of a Transtibial Prosthetic Socket through Integration of QFD, Reverse Engineering, and 3D Printing

Rosnani Ginting ORCID..., Aulia Ishak ORCID..., Fadylla Ramadhani Putri Nasution ORCID..., Rinaldi Silalahi ORCID...
Department of Industrial Engineering, Faculty of Engineering, Universitas Sumatera Utara, Medan, North Sumatra, 20222, Indonesia

This study focuses on addressing the challenges faced by individuals with physical disabilities, particu-larly lower body impairments, by developing a stump socket using Reverse Engineering (RE), 3D Printing, and QFD. The integration of these three methods is something new in product design devel-opment, especially prosthetic products. The research adopted a three-step methodology: 3D scanning the stump, obtaining precise measurements, and fabricating a stump socket using fused deposition modeling (FDM) technology. QFD will produce technical requirements (TR) derived from consumer needs and brainstorming with prosthetists. TR will be the basis for developing the socket design in the 3D Scanning phase. The scanning process utilized Polycam, and the 3D models were refined with Meshmixer. The socket was fabricated using PLA+ material to ensure cost efficiency and customiza-bility. Experimental results demonstrated the accuracy and feasibility of the designed prosthetic sock-et, with a layer thickness of 0.2 mm and printing temperatures up to 215°C. The study highlights the potential of RE and 3D Printing to address the unique anthropometric variations of Indonesian users, overcome the limitations of conventional crutches, and reduce production costs compared to imported prostheses. This approach demonstrates a scalable and innovative solution to improve accessibility and quality of life for individuals with physical disabilities while contributing to economic inclusivity.

Keywords: Transtibial Prosthetic Socket, Reverse Engineering, 3D Printing, QFD
Grants and funding:

The authors are grateful for the financial support from Talenta Universitas Sumatera Utara grant number: 23088.1/UN5.1.R/PPM/2024. The authors are also grateful to the Faculty of Engineering, Universitas Sumatera Utara for providing Research Development Funding Batch II 2024

Received: May 24, 2025; Revised: December 3, 2025; Accepted: December 22, 2025; Prepublished online: December 22, 2025; Published: December 23, 2025  Show citation

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Ginting R, Ishak A, Nasution FRP, Silalahi R. Innovative Design of a Transtibial Prosthetic Socket through Integration of QFD, Reverse Engineering, and 3D Printing. Manufacturing Technology. 2025;25(6):778-787. doi: 10.21062/mft.2025.085.
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