Design parametrizado em manufatura aditiva de pé protético modular com filamento de compósito polimérico reforçado com fibras descontínuas de carbono

Abstract

Discontinuous Fiber Polymer Composites (DFPC) have emerged in Additive Manufacturing (AM) as promising alternatives for the development of products with high geometric complexity and optimized mechanical performance. These materials offer favorable mechanical properties, while the application of AM contributes to improved structural performance through different deposition and build orientations. In addition to reducing raw material waste compared to conventional processes, such materials also enable the customization of solutions across different sectors, including the biomedical field. In the context of pediatric prosthesis manufacturing, particularly transtibial devices, a critical issue arises from the frequent need to replace these devices during the child’s growth, generating significant environmental, economic, and social impacts. This dissertation aimed to develop an original parametric and modular model of a pediatric prosthetic foot, designed under the principles of Design for Additive Manufacturing (DfAM) using Fused Filament Fabrication (FFF). The proposed model offers an adjustable device that adapts to the patient’s growth stages, minimizing waste generation and optimizing manufacturing efficiency. To support the design, tensile tests were conducted on DFPC specimens, evaluating different build orientations and filament deposition directions. The results indicated that the combination of lateral build orientation with a 0° filament deposition angle (relative to the print bed) provided the best mechanical performance, highlighted by the highest ultimate strength (40.33 ± 1.61 MPa), establishing these parameters as optimal for the proposed prosthesis production. As a scientific and technological contribution, this research introduces the “Use and Reuse SUS Cycle,” a system tailored to the Brazilian Unified Health System (SUS) context, aimed at reducing costs through the reuse of adjustable prosthetic modules. Additionally, it proposes the integration of conventional prosthetic manufacturing processes with AM technologies and 3D scanning.