Adjustable prosthetic sockets: a systematic review of industrial and ...

23 Jun.,2025

 

Adjustable prosthetic sockets: a systematic review of industrial and ...

The literature search identified 38 articles, with seven additional articles added through snowballing, and 5 added from the repeated search in (Fig. 1). The 50 articles spanned a total of 35 different socket designs. The patent search identified 63 patents of which 22 were linked to ten companies with active products and four university institutions (Additional file 1: Appendix—Table S1). The news articles linked to eight active companies and one research institution, all of which had been identified via the patent search. Finally, four additional companies known to the authors were added [20,21,22,23], giving 14 companies that currently provide adjustable sockets. Seven of the 14 companies produce prostheses for multiple levels of amputation. If multiple products within a company shared the same design characteristics, then these were grouped as one design. This analysis led to the identification of 16 commercially available designs (Additional file 1: Appendix—Table S2).

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The patent search identified 73% of the industrial designs discussed in this review. One identified patent was connected to Washington University [24], and this team also contributed to 22% of the literature articles, showing that they are a key player in the field. The authors from the three other universities who released patents are not linked to any identified literature results. Twelve of the identified patents were linked to companies that did not provide a currently available adjustable socket (Additional file 1: Appendix—Table S1). From the date of the patents, it can be assumed that some come from companies which no longer exist, and others describe designs which are either no longer available or yet to come to market. 73% of identified patents and literature publications fell within the last ten years (Fig. 2).

Results—adjustable socket categorisation

Based on the descriptions and images available for each design in the report or webpage available, two key design characteristics affect how the socket geometry changes shape. These are the principle of adjustability and the form of the surface that contacts with the residuum when adjusted (Table 2). These two factors were used to group the designs from our search results (Additional file 1: Appendix—Tables S2 and S3). One commercially available product [25] is provided as a system rather than a manufactured socket. They recommend different designs which places it in multiple principle of adjustability categories. In this case, as the surface form can only be evaluated once manufactured, it is excluded from surface form categorisation under industry designs.

Principle of adjustability

The most common adjustment method used in literature was inflatable bladders, whereas this was the least popular approach amongst commercially available designs. Moveable panels showed similar distributions across literature and industry, with hinged designs being the least popular. Only 14% of literature designs included multiple principles of adjustability, compared to 25% in industry. In four of these designs, variable length was a secondary principle of adjustment alongside circumferential adjustment, and one design detailing a concept containing moveable panel and circumferential adjustment. Most adjustability mechanisms can be user-adjusted, however in some designs length adjustment can only be implemented by the clinician.

From the 34 studies identified, the median number of participants is ten, however eight studies only included a single participant. Some of the case studies were focused on individuals with specific needs such as a bulbous residuum [26], whilst most others were aimed at demonstrating a proof of concept of a new design.

Inflatable bladders

Inflatable bladders could be a part of the liner (e.g. Sanders et al. [27]), or socket (e.g. Seo et al. [28]), both with similar purposes and outcomes. However, here we are only discussing designs intended to be incorporated into the socket. From the 17 research articles on inflatable bladders, only seven reported undertaking studies involving participants, three of which included only one participant. All the inflatable bladder designs, both commercial and research, were classified as conformable surface form (Fig. 3).

The sole industry design by Epoch Medical only contains one bladder on the posterior surface of a transtibial socket. The associated patent and product has a pump located at the socket’s distal end, before the pylon, which automatically adjusts the bladder pressure [29]. However a more recent patent and associated website details a new manually adjustable bladder system where the pump is located on the posterior aspect of the socket [30, 31].

Moveable panels

Movable panel sockets are mostly rigid in form with certain sections able to move relative to the rigid section. There are two subcategories—floating (Fig. 4a) and hinged panels (Fig. 4b). Floating panel designs are usually classified as having a rigid surface form due to their material composition, with multiple DOF of movement due to their ability to accommodate small translations or rotations. Rigid single DOF panels, which can be floating or hinged, are only free to either translate along or rotate about one axis. How the panel is attached to the rigid section of the socket can determine which category it falls under and influence what form the panel surface may have. The surfaces of the moveable panels are built up with thicker panels enabling a greater reduction in socket volume (Fig. 4a). The material used is usually a firm foam to generate compression of the residuum, however if a softer material was used then the surface form could be classified as conformable.

In moveable panel designs, where the adjustment is local rather than across the whole socket, adjustment locations were generally justified based on load tolerant regions of the residuum or specific prosthetist advice. Lower limb sockets typically included either a single large posterior adjustable section, or three smaller adjustable sections (para-tibial and popliteal regions/ anteromedial, anterolateral, and posterior midline). For upper limb sockets, adjustable sections were placed at optimal myoelectric control locations. When a design has multiple panels they can either be adjusted by a number of actuator mechanisms, i.e. independently of one another [21, 32,33,34], or by a single actuation mechanism [33, 35,36,37]. Using a single actuator mechanism reduces the number of components required and the complexity of socket manufacture, however this creates an underactuated system where the same repeated input could create different internal socket geometries.

From the 14 studies of moveable panel sockets, the median number of participants was 12, with one article using a single participant. In addition to these studies, three articles detailed no participant involvement. In literature, the rationale behind moveable panels changes depending on the anatomical location of the socket. Ten studies concentrated on residual limb fluid volume retention and recovery (all in transtibial populations), with only three concentrating on volume fluctuation accommodation (transtibial, transradial and transfemoral) or electrode contact (trans-humeral).

Circumferential adjustment

The circumferential adjustment designs are characterised as either ‘gap/overlap’ or ‘struts’, with both being adjusted by straps or wires which travel circumferentially around the socket wall. Gap-based designs [38,39,40] and overlap designs [41,42,43,44,45] work by having an area of the socket, which when adjusted allows the circumference to change (Fig. 5b). The control mechanism for adjusting the socket is often placed over this area, making its location determined by user access.

Strut-based designs [46,47,48,49,50] consist of multiple longitudinal struts, often four, where each strut can flex/move independently (Fig. 5a). Some designs have the struts located against the liner to act like a conventional socket wall, whereas others allow for a gap between the struts and the residual limb, with contact only at the proximal end of the socket where the adjustment straps are located. Two socket designs [46, 50] can change the diameter of the socket at the distal end specifically by changing the radial distance between the longitudinal struts at their connection to a distal end plate, as well as providing more general circumferential adjustments throughout the socket’s length. For both designs, the distal end plate radius is changed manually, with the socket doffed, by the prosthetist.

Of the 18 articles covering circumferential socket designs, 13 involved participants, with a median number of six. Seven of the studies were conducted on transfemoral socket designs with the rest being a range of other anatomical locations. Accommodating volume fluctuations and the associated comfort of achieving this were the motivations behind most of the studies. Nearly 80% of the studies focusing on industry socket designs were clinical studies of circumferential socket designs.

Variable length

Socket length adjustability was only identified alongside circumferential adjustments. The variable length design by Hallworth et al. [51] is fully modular and the actuation mechanism for adjusting the socket volume can move longitudinally along the socket wall. As well as changing the socket length, this gives additional freedom in dictating where actuation and maximum compression may occur. The Connect TF [52], which is only clinician adjustable, uses the overlap technique to provide both its circumferential and length adjustments meaning the socket still encapsulates the residuum whereas the Varos socket [45] (Fig. 6) appears to just move the distal end connection away from the bulk of the socket. Finally, the LIM Innovations Infinite Socket TF [50] has an adjustable ischial seat height, varying part of the devices length, which is adjustable by prosthetists.

Surface form

Considering the designs according to the surface which is moved into contact with the residuum when the socket is adjusted, these can be characterised as conformable, rigid with multiple DOF, or rigid with a single DOF. Both literature and industry have shown very similar distributions by surface form (Table 2). However, use of inflatable bladders to deliver a conformable surface form was much more commonly seen in academic papers (89%) than in industry (17%). In industry, the additional conformable surface form designs were upper-limb circumferential adjustment sockets, consisting of fabric- and/or strap-based designs. However in literature only one upper-limb conformable surface design, categorised as a moveable floating panel design [53], and one lower-limb design, which is circumferential adjustment [54], were found. Only one design was found in literature which used circumferential adjustment specifically for upper limb and this had a rigid surface form with a single DOF of adjustability [51]. All the rigid multi-DOF surface forms fall within the moveable panels principle of adjustability across both literature and industry.

Design variations

One research device by Ogawa et al. [55] used a magnetorheological fluid, which displays increased stiffness when exposed to a magnetic field, enabling the socket to have variable stiffness characteristics. This system resembles a device with fluid filled inflatable bladders, but when the magnetic field is applied the socket has the same characteristics as a rigid socket. Similar to this, the design discussed by Ibrahimi, Gruppioni and Menciassi [56] consists of an inflatable bladder built into the socket wall between two layers of jamming chambers. The jamming chambers are soft when at atmospheric pressure and become stiffened when the air pressure inside is reduced by vacuum. By pressurizing the different layers in order, the local stiffness characteristics of the socket wall can be changed allowing the socket to reduce in internal volume. Once reduced in size, the innermost jamming chamber is vacuumed to enable the socket to increase in stiffness and retain its new shape. Only one research device [57] combined moveable panels and circumferential adjustment into one concept. In this design the moveable panels are automatically adjusted using C-shaped shape-memory-alloy to provide a constant force by the panel, with the circumferential adjustments available to adjust the socket to suit the residual limb shape and size.

The two most recent patents are for socket designs that are a mesh of small, repeated components with specified tension between them, which claim to allow the socket to deform around the residual limb as it changes shape [58, 59]. This approach differs from the gap designs discussed above as there is a gap between each individual component rather than just at one location, but these could still be classified under circumferential adjustment.

Actuation mechanisms

We identified three main actuation mechanisms used across literature and industry: micro-adjustment dials, straps, and pumps or motors (Fig. 7). Some designs, including syringes used to increase/decrease fluid bladder volumes, and external motor or pump systems to control socket volume, were not practical outside of a laboratory environment. External control hardware in research-based devices is often bulky, potentially compromising cosmesis and device robustness. For this reason, any method of actuation deemed to be impractical to be used in everyday life was removed from this section of the review.

Micro-adjustment dials

Micro-adjustment dials are used to control cables which pass through the socket and adjustable regions. The most common design is the BOA dial [60] although other devices were also identified. These systems provide near continuous adjustment due to small increments of cable shortening when the dial is turned. All the commercially available designs which use cable driven control are manually adjusted by the user [25, 45, 52, 61].

Straps

Straps are generally positioned laterally around the external circumference of the socket and adjusted manually by the user. Some strap designs, such as those which utilise Velcro, provide continuous levels of adjustment whereas other systems such as leather straps or buckles [44] provide discrete levels of adjustment. The continuous systems, by nature, provide infinitely more adjustment levels over discrete systems, however discrete systems provide greater repeatability in setting adjustment levels. In lower limb research, Velcro straps appear to have been replaced by buckles to accommodate greater loads due to weightbearing, whereas industrial upper-limb sockets still use Velcro straps.

Pumps or motors

Pumps are used to control bladder-based systems and can provide a continuous range of adjustment by adding or removing air or liquid to one or more bladders. Some pumps also utilise control systems which are set to discrete levels predefined by a prosthetist based on specific socket pressures or limits, or even utilise automated control to maintain a predefined internal pressure level. Motors work similarly and can be used to pull panels towards the limb [35, 36, 62]. In these designs, the motor simply replaces the micro-adjustment dial and can be controlled remotely by either the user or researcher. Alternatively, with the inclusion of sensors to monitor the limb to panel distance, the motor can be controlled automatically to maintain socket fit throughout limb volume fluctuations [37].

Cosmetics

From all the literature results only three articles [38, 39, 63] mentioned covering the adjustable socket with a cosmesis. All three studies involved participants wearing their adjustable socket outdoors which could explain their inclusion of a cosmesis, and interestingly these were also three of the earliest of the identified studies. With adjustable sockets available in industry, a similar distribution can be seen with only two companies [20, 64] mentioning the option of covers, both offering a choice of colours and designs.

Other results

A range of methodologies were utilised to test the sockets and their principle of adjustability. When trialling lower limb devices, typical assessments such as the two-minute walk test and cycles of sitting and standing were used. These were predominantly carried out in controlled environments, such as a gait lab, and the studies typically examined the influence of the fit of the socket on the residual limb fluid volume. The assessment of upper-limb sockets focused more often on range of motion, mechanical performance and the ability of the socket to achieve good contact between an EMG (electromyography) sensor and the residuum (in designs intended for EMG controlled prostheses).

Only 17.1% of research designs focused on upper limb prosthetics, compared to 37.5% of commercial devices. None of the identified literature investigated both upper and lower limb adjustable sockets in the same study. Only one company [65] offered design concepts available for both the upper and lower limb, however, 47% of companies designed adjustable sockets for multiple lower limb amputation levels (e.g., transfemoral and transtibial sockets). In lower limb adjustable sockets, transtibial design are more prevalent than transfemoral in literature, 48.6% and 25.7% respectively, whereas the split is more even in industry, 43.8% and 50%.

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Most prevalent in literature (77% of designs) were custom sockets, which are made to match the patient’s residuum shape without premanufactured component restrictions, likely due to the lack of industry partnerships present. In contrast, only 25% of industry designs are categorised as custom, however it must be noted that this is representative of the number of designs available and potentially not an indication on the quantity of sales or patients who use the devices. Only nine research articles cover the five different commercially available sockets used (Fig. 8). Two papers used the Click Medical RevoFit system [25], which is built into a custom socket, to build different designs of adjustable socket, with others appearing to use similar systems. This leaves 68.75% of identified commercial designs not associated to any identified research. One article by Greenwald, Dean and Board [66] discussed an inflatable bladder socket design with links to an industry company. The same socket design and associated industry connection was also made within the patent search, however no active product could be found.

The World Health Organisation (WHO) provide guidance on how research evidence should be interpreted to inform clinical decisions [67], referring to the hierarchy of internal study validity proposed by Murad et al. [68]. In prosthetic research, higher levels of evidence such as randomised control trials, and blinded studies, are known to be scarce [69]. The WHO however does recognise the need for lower-level studies to answer certain research questions. Of the 34 studies identified in this review, 18 arewere case studies, seven repeated measure studies, eight are cohort studies, and one did not disclose enough information to be categorised (Additional file 1: Appendix Table S3). Repeated measure studies are used over case control studies as they reduce the number of participants required, which is a known difficulty which limits prosthetic research.

This discussion addresses the design characteristics of the sockets, justification for the adjustment, and the limitations and safety of each design. The clinical studies were analysed to assess their scope and outcomes, both as an overarching assessment of adjustable sockets and in each principle of adjustability group. The control methods used are discussed, as well as the importance of cosmesis in design.

Design justification

With patents and commercially available products, it is difficult to establish any justification behind design decisions as the content presented is either focussed on covering as broad a set of possible embodiments as possible (patents) or advertising the features and associated benefits of a product. In both cases, we found very few associated research publications. Interestingly, the information available through the Click Academy [40] describes how various design approaches may present different benefits to the user, however the research behind these claims is not presented. Instead, clinicians can share their custom designs for individual case studies, which provides some clinical evidence, but from small sample populations. Some companies [44, 64, 70] present research on their websites, some of which appeared in our literature results [41, 43, 49, 71]. Ottobock also have a clinical research area to their website [70], but the paper describing a clinical study of their socket [42] could not be found through it.

It was common across all adjustable socket designs for research studies to include clinical expertise to judge whether the initial socket shape had too tight or loose a fit, or to alternatively begin by duplicating the shape of the participant’s current clinically manufactured socket. These two options are likely favoured as there is limited research to guide decisions around socket fit. Several papers discussed creating a metric or pressure measurement when the socket had a good fit, often based on a prosthetist’s assessment, and then attempting to maintain this through adjustment [28, 66, 72]. An alternative method involved obtaining an approximation for the pressure limit of the residuum tissue, through indention testing [73] or numerical modelling [74], then restricting adjustments to that limit. It is also worth mentioning that using interface pressure alone has been shown to be a poor predictor of tissue damage, as similar interface pressure magnitudes often translate to considerably different internal tissue loads. This depends on factors such as the presence of bony prominences, and soft tissue characteristics [75], which can vary in amputee populations where comorbidities such as diabetic muscle infraction and neuropathy are more prevalent. Despite this, articles relating to inflatable bladders often justified their design through their ability to maintain a constant internal socket pressure [28, 66] or developed an algorithm which adjusted the bladders automatically in specific regions of the residual limb, depending on the pose of the arm (detected by an accelerometer [72]). Articles involving moveable panels rarely justified their design approach. In our opinion, moveable panels are the easiest principle of adjustability to standardise in manufacture and can be quantifiably evaluated, which could explain the popularity of their use within research and clinical practice.

Socket adjustment

The range of adjustment made was most commonly reported as the percentage change in socket volume. Some articles referenced the estimated limits of a “good” and “acceptable” fitting socket, which are 5% and 10% change in socket volume respectively [76]. However, we did not find any research which compared the effects of varying the volume locally, as seen with moveable panels, or varying the volume generally, on the quality of fit, socket performance, as well as comfort and tissue health. This may well be dependent upon shape and tissue composition of each individual’s residual limb. Other studies had the range of adjustment determined by the participant themselves.

Small user adjustments are designed to accommodate low-level residual limb volume fluctuations or to increase the ease of a task, such as donning the socket [26, 44, 45, 61, 77]. Clinician adjustments are usually designed to alter the socket geometry to accommodate larger physiological changes without needing to redesign the socket or replace major components [46, 47, 51]. Together, these enable off-the-shelf and modular prosthetic sockets to be feasible, with one device potentially being suitable for a range of patients with varying residual limb sizes and shapes [15].

Principles of adjustability

One limitation is that no sockets were purchased for physical inspection by the authors for the purpose of this review, therefore some assumptions on the details of how socket adjustments are achieved have been made, due to the limited detail provided within the literature and patents.

The proposed benefit of using inflatable bladders over alternatives is that they can control interface pressures, rather than volume, and can focus on local areas or the whole residuum. In order to achieve a consistent internal socket pressure, some designs consisted of multiple connected bladders covering the majority of the socket’s internal surfaces [28, 73, 78, 79], whereas others placed the bladders over specific load tolerant areas [66]. The evolution of the Epoch Medical design shows the relative difficulty in incorporating the required control system to automatically adjust an inflatable bladder into a conventional socket without adding weight. Such designs are also relatively complex, and hence introduce an additional risk of failure.

Moveable panels are cut to size, often from a fixed geometry socket, which ensures that the rest of the socket achieves a good fit, and only the load tolerant regions chosen are adjusted to accommodate limb volume fluctuation. The potential influence of panel size and locations on comfort and the mechanical coupling performance of the socket is unknown, with none of the studies investigating or discussing the relationship between coupling, comfort, and functionality. Adjustable sockets are well suited for investigating this due to the ease and relative repeatability with which the panel characteristics can be varied and adjusted to change the fit of the socket.

When considering underactuated moveable panel systems, it is unknown whether the panel with the least resistance (i.e., lowest interface pressure) would move when the socket is adjusted or whether the internal friction of the system from the wires would make panels closest to the dial actuate first. The actuator to panel ratio and its influence on adjustments is an area requiring future research, as an underactuated system could provide the freedom for the socket to adjust where needed.

Some designs presented through the Click Medical Academy [40] show how moveable panels can be used to aid the donning process and socket suspension, particularly with sockets intended for joint disarticulations where the distal aspect of residual limbs can be more bulbus. This demonstrates the potential versatility of this design compared to others.

In circumferential adjustment gap/overlap designs, the flex in semi-rigid socket material allows the socket to change shape. As a result, the control mechanism on the socket can only provide a force to reduce the socket volume from its manufactured shape, any flex in the other direction would be driven by an internal socket force to increase the effective volume. In strut designs, due to the ability of each strut to move independently of one another, the change in socket volume might occur where the residual limb has changed shape or where the residuum can accept additional compression. However, these struts are quite stiff, limiting the amount they can conform to the shape of the limb. Strut designs, where there is space between the struts (Fig. 5a), allow for small volume fluctuations of the limb to occur without needing to adjust the socket and maintain a consistent socket fit, meaning the socket can cope with a larger range of volume changes than other designs. This makes them ideal for residual limbs which see large daily volume fluctuations. However, this increases the potential for the socket to have areas which are overtightened, which could lead to discomfort or tissue damage, or over-loosened, which could adversely affect the mechanical coupling and functionality. One study reported a small drop in comfort after completing a mobility test, when compared to their current socket, as the single participant could feel the struts flexing whilst ambulating [46].

As discussed, variable length was only available alongside other principles of adjustability. This is particularly useful when using adjustability to make off-the-shelf sockets viable for low resource settings. The clinician can set the length and circumference of the socket to specific dimensions based on the geometry of the patient’s residual limb, with the user being able to only make subtle adjustments away from this setting, reducing the need for custom socket design and manufacture. This is particularly effective with upper-limb socket design, due to the relatively smaller residual limb volume fluctuation, with examples of this seen in commercially available devices from Martin Bionics (Socketless Socket) and Toughware (ITAL) [23, 65]. Despite these designs existing only the Toughware mentions low resource settings, likely due to the majority of funding in prosthetics coming from high resource countries.

Safety and limits

Due to the low number of inflatable bladders designs, the safety of these devices is difficult to evaluate. However, this principle of adjustability could be considered safer than other devices with respect to tissue loads seen, due to the constant pressure nature of liquid- or air-filled bladders. On the other hand, the risks associated with the bladders either leaking, bursting, or delaminating from the socket, are unique to this type of device.

Although in research studies of liquid-filled inflatable bladders, liquid can be added from an independent reservoir, practical designs are limited by the amount of liquid that can be stored on the prosthesis. Air bladders show greater potential as they can operate without the need for a reservoir. In both cases, the socket shape can only be reduced from an initial geometry, meaning the sockets are cast and manufactured at maximum residuum volume for the intended user, or the socket design would be restricted to accommodating limb volume reduction only. Further to this, whilst it is feasible to change the volume of the bladders occasionally throughout the day, the designs which require the bladder volume to adjust during the gait cycle are limited by the combination of the fluid’s viscosity and the pump flow rate.

Moveable panels and circumferential adjustment gap designed sockets have a visually obvious and defined minimum volume for the socket. In moveable panel designs, the panel thickness can be customised to control the limit on socket volume reduction, which can be seen by the user as the panel becomes flush with the rigid socket. Likewise in custom circumferential adjustment gap designs, the gap shape and size can be personalised to suit the individual’s range of residuum volume fluctuations. As this gap closes, the material stress is theoretically dispersed throughout the socket wall, however with the nonuniform shape of a socket wall and uneven internal pressures provided by a residuum, this is unlikely the case and makes it unclear whether adjustment of the socket affects local or whole socket geometry. This suggests that these sockets have less control over the specific location that socket volume change occurs when compared to other principles of adjustability, potentially causing localised discomfort and tissue damage. However, this could design some freedom into the socket to function as an underactuated system, adjusting the socket shape where required. Further research is required into circumferential sockets to understand how the socket shape and location of the gap/overlap influence where the socket volume is adjusted. Designs which offer localised adjustment rather than whole volume, such as moveable panels, could be safer than circumferential adjustment devices due to their ability to focus load on load tolerant regions and avoid areas which are sensitive to loading and at risk of tissue damage.

Clinical studies

The low participant numbers perhaps reflect the relatively early stage of this field’s development and may also reflect the relatively small population of eligible research participants, particularly those with upper limb absence.

The upper-limb study tests were exclusively carried out in controlled environments (such as a laboratory), and rarely examined the impact of adjustment once the socket was fitted, probably due to the upper limb experiencing much less volume fluctuation when compared to lower limbs [80]. Importantly, studies were often short-term in duration regardless of whether they focussed on upper or lower limb adjustable sockets, greatly limiting the extent to which the safety and durability of these devices could be tested.

In the four studies of inflatable bladder devices, which included multiple participants, each had different aims and outcome measures, reducing the ability to extrapolate the findings. Some concentrated on residual limb fluid volume and recovery and others focussed on residuum-socket interface pressure. One study [79] found that increasing bladder volume and therefore interface pressure reduced residual limb volume in a high proportion of participants. Interestingly, optimal self-reported comfort across studies was associated with different bladder pressures between participants, highlighting the subjectivity involved with obtaining comfort data.

Higher participant numbers in moveable panel studies could be related to the ease with which moveable panels can be incorporated into a prosthetic socket. Some studies showed that moveable panels can effectively aid in the retention of residual limb fluid during exercise and rest [32, 33], however these studies used motors to positively detract the panels to facilitate this recovery. Whilst effective in illustrating that the resulting vacuum is beneficial to the user’s tissue health, conventional actuation mechanisms do not offer this function. This is therefore an example of adjustable sockets being designed to test a research question rather than as a commercially viable design. Very few moveable panel studies included an outcome measure of socket comfort, despite this being the major outcome measure used in UK NHS clinics. Those few papers that did report comfort were inconsistent in their methods, with some comparing between adjustable settings and others comparing to previous socket designs. One study [34] included a subjective measure allowing participants to comment on why the comfort changed between adjustment settings. The range of comments shows that there is a need for a more in-depth socket comfort outcome measure to be established to allow consistent reporting on how different adjustable socket designs influence participant comfort. In contrast to the studies on inflatable bladders and moveable panels, over half of the studies on circumferential adjustment sockets included a verified and established method for assessing comfort. The majority of these reported improvements in comfort when using the adjustable socket over the participants’ original/current sockets, however no reasons are documented as to why this occurs. Future studies should assess how comfort changes between, and whilst set at, different levels of adjustment, as well as the effect of the location of adjustment on comfort.

Further outcome measures used across the clinical studies included bioimpedance measures of residuum fluid volume, internal socket pressure measurements, and subjective comfort and pain scores, but the use of these varied greatly from study to study making it difficult to compare the designs used in different studies, particularly as no clinical study compared different designs of adjustable socket. Many of the studies also used the internal socket pressure to inform how tight the socket was fitted, which may also have been a factor in improving the socket comfort, as it prevented the socket from being overtightened in order to achieve a better mechanical coupling between the residual limb and socket. The literature was less clear on whether an adjustable socket improved gait. If adjustments were controlled to ensure comfort, with pressure kept to a reasonable level, it is possible that observed changes to gait could have been driven by improved comfort. The relationship between changes to coupling and gait are difficult to study without careful study design and hence there is a need for further research investigating how an adjustable socket affects both comfort and coupling, and the challenges in achieving a compromise between them.

The Medicines and Healthcare products Regulatory Agency (MHRA) recognise prostheses are made up of two separate parts: the prosthetic socket, and the hardware (everything else). They stipulate that prosthetic sockets can be either a Class 1 medical device in their own right, or custom made by a clinician to manufacturer guidelines [81]. Despite some adjustable prosthetic sockets being Class 1 medical devices, and many likely having the potential to cause harm if improperly adjusted, of the 34 research studies involving participants only five reported on adverse events. The short-term nature of studies may also be contributing to a potential under-reporting of risks.

Actuation mechanisms

Micro-adjustment dials

The maximum tension within the cable, and therefore pressure applied by adjustable sections, is limited by the strength of the cable and dial used, which are not visible to the user. There is therefore the potential for the user to continue tightening until the socket reaches its minimum designed volume. Another disadvantage of these dials is that when mounted to the external surface of the socket, they stand proud compared to the rest of the socket, compromising cosmesis (Figs. 4b and 7a). The dials could also catch on clothing or other objects, causing damage and affecting function. Often designed to work with laminated sockets to protect the cables, micro-adjustment dials may only be viable in clinics where lamination capabilities are available.

Straps

Both continuous and discrete strap mechanism can be easily designed to include restrictions to prevent the user from over or under tightening their socket, as can be seen on the system used by iFit Prosthetics [44] which provides discrete levels of adjustment. The disadvantage of Velcro is that any adjustments require the Velcro to be completely undone before being reapplied, making small incremental changes more difficult.

Out of all the control mechanisms discussed, straps are the easiest to implement as they can be manufactured from materials already used in prosthetics and orthotics clinics and are cheap to purchase. This factor is particularly important for clinicians working in low resource settings. Furthermore, straps have a relatively low profile relative to the socket compared to the other two control mechanisms (Fig. 7). Straps raise few safety concerns as a control mechanism. However, continuous strap systems have the potential to slip when under higher forces and straps made from leather or polymers/plastics may stretch and break over time.

Pumps or motors

Pumps and motors enable the clinician to provide specific limits to adjustments, preventing the user from overtightening or loosening their adjustable socket. This is a key safety feature when utilising this actuation mechanism as the potential range of adjustment without any form of restrictions could be quite large.

The disadvantage of these actuation mechanisms is that the additional components need to be positioned somewhere on the prosthesis. Epoch Medical [30]; Greenwald, Dean and Board [66]; and Washington University [35,36,37, 62], all position these at the distal end of the socket along with the reservoir of additional fluid or cable (Fig. 7c) adding bulk and weight to the prosthesis. Its distal positioning increases the inertia of the limb, potentially affecting gait and the ease with which the limb is controlled. Due to the size of these components, these designs may not be feasible on trans-tibial or trans-radial prostheses for individuals with longer residual limbs where space is limited. As the control mechanism is mounted away from the adjustable locations, the fluid or cable routings also need to be included into the prosthetic socket, further complicating the design and manufacturing process.

Cosmetics

A cosmetically pleasing or inconspicuous prosthesis can be a key factor in increasing prosthesis satisfaction and embodiment [82].The majority of more recent clinical studies were lab based and it appears the issue of cosmesis was of less importance when compared to the need to observe and interact with the socket and its adjustable components. The low number of companies offering covers is surprising considering that these products are intended for everyday use. This lack of covers, or cosmeses, is likely down to the need to access the control mechanisms which are positioned on the external socket wall, along with the cover needing to adapt to the changing socket shape. This is avoided on the LIM Innovations TT-S [61] socket as the cover is loosely fitting and the adjustment dial has been lowered away from the socket wall, so that it is outside of the cover. The lack of covers could also be due to the increased number of aftermarket covers, or wrap-arounds, becoming available, providing a bespoke appearance.

Patent search methodology

Although 73% of the companies were discovered through the patent search, over 60% of the patent results could not be linked to either companies with active products, or to research institutions, indicating that the patent search criteria could be further refined in the future to identify relevant and appropriate patents more accurately within this field. Using the same search criteria for both the literature and patent searches would have reduced its effectiveness further as patents are often given more generic names than research articles; an example of this is the increased use of the word ‘system’ in patents over literature.

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A prosthetic leg can be life-changing, helping you walk, stand, and regain independence after losing a limb. But choosing the right one, understanding how it works, and adjusting to life with it can feel overwhelming.

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From the different types and components to the process of fitting and ongoing care, there’s a lot to learn. This guide breaks it all down, making it easier for you to get back to doing the things you love.

What is a Prosthetic Leg

A prosthetic leg is an artificial limb designed to help you walk, stand, or even run after losing a leg. It restores mobility, enhances your quality of life, and gives you the chance to be active again.

Modern prosthetic legs are built with strong but lightweight materials like carbon fiber, fiberglass, titanium, or aluminum. Softer parts, such as foam cushioning and silicone sleeves, are added to enhance comfort.

While some people can walk freely with their prosthetics, others may need extra support, like a cane or crutches, for stability.

You might need one due to injury, medical conditions, or birth defects like congenital limb deficiency. It can be:

  • Below-the-knee prosthetics – These are used when the amputation is below the knee and typically include a shin, ankle, and foot.
  • Above-the-knee prosthetics – This type includes a functioning knee joint, which is essential for bending and walking more naturally. Unlike below-knee prosthetics, it must replicate both the movement and stability of a real knee.

You can also choose custom-made prosthetics tailored to fit your body perfectly, or standard models, which are pre-made and more affordable.

Types of Prosthetic Legs

Prosthetic legs vary not only in design but also in the technology used to support movement and stability.

  • Mechanical prosthetics – These rely on pneumatic or hydraulic systems (compressed air or water) and other mechanisms to help you stand, walk, and carry out daily activities. They’re known for being durable and reliable, making them a practical choice for many. They are built to handle regular wear and tear and come in various sizes to fit different needs.
  • Microprocessor-controlled prosthetics – These advanced devices use computerized systems, hydraulics, and sensors to mimic a natural walking gait. They can adapt to different terrains, speeds, and activities, providing better balance and control.

Both mechanical and microprocessor-controlled legs include adjustable resistance systems, allowing smoother and more natural movements.

Components of Leg Prosthesis

The comfort and functionality of a prosthetic leg depend on its materials and key components. These parts mimic natural movement and ensure a secure and comfortable fit.

A prosthetic leg includes several important components:

  • Socket – The part that connects your residual limb to the prosthetic. It’s carefully molded to fit your limb and requires several fittings to ensure comfort and a secure fit.
  • Skeleton – It connects the socket to the joint components, providing strength, balance, and weight support. It’s also known as the connector, adapter, or frame and is often made of a metal pylon with connecting parts.
  • Foot/Ankle – The prosthetic foot is the final part of the leg and may or may not look like a natural foot. It can vary based on your activity level, offering flexibility for walking, running, or standing.
  • Suspension system – It connects the prosthetic to the socket, keeping it securely attached to your leg and preventing it from slipping. It can involve different methods, such as sleeve suction, vacuum suspension, or a locking mechanism using a pin or lanyard.
  • Joints – Above-knee prosthetics include a knee joint and a hip joint in some cases to help replicate natural movement. These joints can be mechanical, pneumatic (air), hydraulic (water), or even bionic (powered), depending on your needs.

Each component is carefully designed to fit your unique needs, making the prosthetic feel like an extension of your body.

The Process of Getting a Prosthetic Leg

Getting a prosthetic leg involves steps to ensure it fits well, functions properly, and suits your lifestyle. It requires careful evaluation, customization, and ongoing adjustments to achieve the best outcome.

Here are the following steps you need to take to get a prosthetic leg.

Step 1: Preliminary Evaluation

The process begins with a detailed evaluation by a team of specialists, including a prosthetist and physical therapist.

They will check the following to determine the most suitable lower limb prosthesis for you:

  • Medical history
  • The strength, shape, length, and condition of your residual limb
  • Your daily activity needs
  • Weight and joint stability
  • Physical health

This ensures that the prosthetic limb complements the patient’s lifestyle and functional needs, thereby enhancing the overall quality of life.

Step 2: Choose the Right Prosthetic Device

Selecting the right prosthetic leg depends on your lifestyle, activity level, and medical requirements. You wouldn't be alone in this step as it needs a team effort involving you, your healthcare providers, and a prosthetist.

A prosthetist is a trained specialist in designing and fitting prosthetic legs. They work closely with you to choose the best components and create a custom socket that provides comfort, stability, and support to help you stay active and safe in your daily life.

Step 3: Residual Limb Shaping

Before fitting the prosthetic, your residual limb must be shaped by wearing a compression stocking, or shrinker sock, to reduce swelling and ensure a better fit.

Your healthcare provider will guide you on how to wear the shrinker sock, which should fit snugly and be worn as much as possible, except during bathing.

Regular check-ins with your prosthetist are essential during this stage, as they will monitor your limb’s size and adjust the prosthetic fit accordingly to ensure maximum comfort and function.

Step 4: Fitting and Custom-Making the Prosthesis

Every prosthetic leg is custom-made to fit the unique shape of your residual limb. It’s designed to be strong, durable, and adjustable to ensure comfort and functionality.

Components like the socket and suspension system are carefully selected based on your needs and level of amputation.

The fitting process begins with your prosthetist taking precise measurements of your residual limb and opposite limb in some cases.

This may involve creating a cast or using a 3D scan to capture the exact shape. They’ll also evaluate which muscle groups you’ll use to control the prosthesis, ensuring the device functions properly.

Several adjustments are made throughout the fitting process to achieve an optimal fit. Proper prosthetic alignment is essential to promote a natural gait and reduce the effort required to walk with the prosthesis.

Customization must consider your specific mobility requirements, including:

  • The ability to move
  • Maintain balance
  • Handle obstacles
  • Adapt to different walking speeds

Achieving the right fit ensures the prosthesis enhances your mobility and supports your daily activities effectively.

Step 5: Training with Your Prosthetic Leg

Once your prosthetic leg is ready, your prosthetist will guide you through basic training:

  • Putting it on and taking it off
  • Cleaning
  • Operating any mechanical parts
  • Charging electrical components if your prosthetic includes them

After the basics, you'll begin the physical and occupational training process to practice using your artificial leg for everyday activities. Therapists will guide you through exercises to strengthen muscles and improve movements like walking and balancing.

Mental health care is also an important part of the rehabilitation process. Adjusting to life with a new prosthesis can be emotionally challenging.

So seeking support from mental health professionals or peer groups can help you cope and stay motivated during your recovery journey.

Cost and Insurance Coverage

The cost range for lower leg prosthetics can be from $3,000 to $120,000, depending on the complexity and the technology they include.

These advanced features can include microprocessors, hydraulics, and materials that provide greater comfort and functionality.

While these costs might seem daunting, it’s important to note that medical insurance typically covers at least part of the cost of lower leg prosthetics.

Insurance Coverage

Many insurance plans will partially or fully cover the cost of prosthetic legs and associated services. However, individuals must verify the extent of coverage and any prerequisite authorization with their insurance company.

Here are some insurance options that may cover prosthetic expenses:

  • Employer-sponsored health plans typically cover a sizable portion of prosthetic expenses.
  • Medicare Part B and Medicaid provide coverage but with certain conditions and co-payment requirements.

It is important to review your specific insurance plan and contact your insurance provider to understand the coverage and requirements for prosthetic legs.

Additional financial support for prosthetics can be obtained from organizations and other foundations, although certain restrictions may apply.

Non-profits can provide financial aid or free prosthetic limbs for those in need. Here's how you can get a prosthetic leg for free.

What to Expect in Life with a Prosthetic Leg

Living with a prosthetic leg can bring both new opportunities and challenges. While it helps restore mobility and independence, adjusting requires time, patience, and ongoing care.

Physical Therapy and Rehabilitation

Physical therapy is essential for building strength and learning to use your prosthetic leg confidently.

Therapists will guide you through exercises to improve balance, mobility, and gait patterns, ensuring a smooth transition to using the prosthetic in daily life.

A key focus of rehabilitation is maintaining the health of your remaining leg, as no prosthetic can fully replicate the function of a healthy limb.

Your rehabilitation team, including physicians, physical therapists, and occupational therapists, will create a personalized plan to help you regain mobility and independence.

Challenges and Complications

Learning to move with a prosthetic leg can be challenging, and even after initial rehabilitation, ongoing adjustments are often necessary.

Some users may encounter additional challenges such as:

  • Excessive sweating (hyperhidrosis) – This can affect the prosthetic’s fit and cause skin irritation.
  • Weakness in the residual limb – This can make it difficult to use the prosthesis for extended periods.
  • Changes in the residual limb – The residual limb can change shape due to weight fluctuations, tissue shrinkage, or muscle atrophy, especially within the first year after amputation.
  • Phantom limb pain – Intense sensations in the missing limb may interfere with prosthetic use.
  • Chafing or pressure sores – Often caused by an improper fit.
  • Cost or insurance complications – Can limit access to repairs or replacements.
  • Mechanical failures – Prosthetic parts may break down and require repairs.
  • Technical difficulties – More advanced prosthetics may have additional maintenance needs.

These changes can affect the prosthetic's fit and require regular maintenance by a prosthetist to prevent discomfort and skin issues.

Your prosthetist and rehabilitation team will help you manage these obstacles by making adjustments, providing gait training, and guiding strengthening exercises to improve your mobility and ensure a better prosthetic experience over time.

Frequently Asked Questions

How long does it take to get used to a prosthetic leg?

The time it takes to get used to a prosthetic leg varies from person to person. Factors like the type of prosthesis, your specific goals, and any complications can all affect your adjustment period.

Rehabilitation and training are done in stages, and it may take several months to a year to feel fully comfortable using your prosthetic leg.

Is it hard to walk with a prosthetic leg?

Walking with a below-knee prosthetic is generally easier than an above-knee prosthesis, especially if the knee joint is intact, as it requires less effort to move and provides more mobility. The reason for amputation and the health of the residual limb can also impact the difficulty of walking.

It would also depend on the type of lower limb prosthetics you have. Mechanical legs are generally simpler but may require more muscle effort to control movements.

On the other hand, bionic legs make walking easier by automatically adjusting for balance, though they can take longer to learn, especially if they’re programmable.

How often do prosthetics need to be replaced?

Prosthetic legs typically need to be replaced every 3 to 5 years, depending on wear and tear or changes in your residual limb. In some cases, your prosthetist may suggest replacing specific prosthetic components rather than the entire prosthesis.

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