Skip to main content
OpenTrials
Completed

NCT Number: NCT06938087

Assessment of Safety and Performances of a 3D Printed Prosthetic Foot: A Pilot Study

A dynamic energy storage and return foot prosthesis is a type of prosthesis designed to mimic and restore the functionality and natural movement of the limb that has been amputated. This type of prosthesis is designed to allow patients to perform daily activities, even very dynamic ones, with greater ease and efficiency. The distinguishing feature of a dynamic energy storage and return prosthesis is the presence of a system that accumulates mechanical energy during the support phase on the ground and returns it during the push phase, increasing the amount of push itself. In foot prostheses, it is common to use carbon fiber blades or springs that deform during the support of the foot and then restore themselves, returning elastic energy during the subsequent push. This helps reduce the effort required to walk and allows for more fluid and natural movements. Additive Manufacturing (AM) technology is ideal for highly customized and high-value production. Orthoses/prostheses are particularly suited to exploit the potential of this technology. However, the lack of functional materials that meet different design needs, such as structure and comfort of the devices, has limited the use of AM mainly in orthoses. AM is promising for orthoses due to its customization capability and reduced production costs compared to traditional solutions. In particular, it has been shown how continuous filament carbon printing can lead to the creation of prostheses that have dynamic and energy return characteristics similar to or even superior to commercial ones. The present pilot clinical investigation aims to provide indications regarding the safety and performance of the 3D printed prosthesis - named PROFIL - in a real-world scenario. The state of the art has not yet defined the performance and safety of 3D printed prostheses with thermoplastic materials and continuous carbon fiber. Since greater comfort and the possibility of performing physical activity more easily with the use of these devices is expected, it is considered of interest for clinical practice to evaluate these prostheses. The primary objective of the study is therefore to evaluate the safety and performance of the device during walking on flat surfaces and more demanding tasks. The secondary objectives aims at evaluate usability and deformation of the 3D printed prosthesis under different loading conditions (slow and fast walking, ascending and descending ramps or steps) by mean of fiber-glass sensors integrated in the prosthesis foot.

Completed

Looking for future studies?

Notify Me

Key information

Age range

18 year–65 year

Sex eligibility

All sexes

Study type

Interventional

Phase

Not applicable

Primary location

Centro Protesi Inail

Vigorso Di Budrio, Bologna, 40054, Italy

Who can participate

Healthy volunteers accepted: No

Only the study team can determine whether someone qualifies for participation.

Inclusion criteria

  • Monolateral below knee amputation
  • Mobility level: K3 or K4
  • Age: 18-65 years old
  • Maximum weigth: 100 Kg
  • Collaborative subject
  • Clinically stable stump

Exclusion criteria

  • Pregnant
  • Not able to understand written and oral instructions
  • Problems to the stump

Treatment and study plan

3D printed prosthesis foot

Device

Energy storage and restoration 3D printed prosthesis foot

Current prosthesis foot

Device

Energy storage and restitution prosthesis foot made in carbon fibers blades

Primary outcomes

  1. Number of Adverse Events Occurred During Use of the Intervention Prosthesis Foot

    Time frame: Day 1 and Day 2

    Adverse events may be: falling, stumbling, lower back pain as consequence of the prosthesis foot use, stump pain as consequence of the prosthesis foot use, breakage of the prosthesis foot

  2. Change From Comparator of Lower Limb Joint Angles Measured With Inertial Measurements Units (IMUs)

    Time frame: Day 1 and Day 2

    The IMUs record joints kinematics while subjects perform a series of motor tasks, i.e. walk of flat surfaces at a self-selected speed and ascend/descend stairs and ramps. In particular, the following variables are measured: range of motion of ankle joint (prosthetic ankle), knee joint, and hip joint of the impaired lower limb. The measured angles are normalized on a gait cycle (0% = heel strike, 100% = toe off). The outocome variable is computed as mean difference between the normalized measured angles and the normalized reference value taken from the literature.

  3. Change From Comparator of Lower Limb Joint Angles Measured With an Optoelectronic System

    Time frame: Day 1 and Day 2

    The optoelectronic system records joints kinematics while subjects walk of a flat surfaces at a self-selected speed. In particular, the following variables are measured: range of motion of ankle joint (prosthetic ankle), knee joint, and hip joint of the impaired lower limb. The measured angles are normalized on a gait cycle (0% = heel strike, 100% = toe off). The outocome variable is computed as mean difference between the normalized measured angles and the normalized reference value taken from the literature.

  4. Change From Comparator of Gait Quality Wihile Ascending Ramps With Hill Assessment Index (HAI)

    Time frame: Day 1 and Day 2

    Hill Assessment Index (HAI) is a 12-points ordinal scale used to evaluate ramp ascending quality; the higher the score the better the gait quality while ascending ramps (0 = cannot do/refuse to do, 11 = even step, without assistive device) .

  5. Change From Comparator of Gait Quality While Ascending Stairs With Stair Ascending Index (SAI)

    Time frame: Day 1 and Day 2

    Stair Ascending Index (SAI) is 14-points ordinal scale used to quantify stair ascending qualty; the higher the score the better the gait quality while ascending stairs (0 = cannot do/refuse to do, 13 = Without rail or assistive device, step-over-step pattern)

  6. Change From Comparator of Equilibrium in Orthostatism by Mean of Force Plates

    Time frame: Day 1 and Day 2

    The subject is asked to stand still on a force plate for 30 seconds. The sway path of the Centre of Pressure (COP) is recorded. The higher the valure the sway path, the lower the equilibrium in orthostatism. This outcome measure is performed with the eyes open and closed

  7. Change From Comparator of Load Simmetry While Standing up/Sitting Down From/on a Chiar by Mean of Force Plates

    Time frame: Day 1 and Day 2

    The subject is asked to sit on a chair with both the feets (sound foot and prosthesis foot) on different force plates. At the "Start" signal, the subject stands up, stands still for 5 seconds and sits down. The weigth distribution on the lower limbs is recorded during the entire task. The symmetry index is computed as the ratio between: the difference between the load peak of the ground reaction force (GRF) measured in the sound side and the load peak of the ground reaction force (GRF) measured in the impaired side ON the sum between the load peak of the ground reaction force (GRF) measured in the sound side and the load peak of the ground reaction force (GRF) measured in the impaired side.

    Asymmetry index = [(peak GRF sound - peak GRF impaired) / (peak GRF sound + peak GRF impaired)]*100%

  8. Change From Comparator of Amputee Mobility Predictor (AMP-PRO)

    Time frame: Day 1 and Day 2

    AMP is a 21-item objectve measure in which static and dynamic sitting and standing activities, as well as transfer and gait skills of progressing difficulty are performed. Score range is 0-47. Higher scores indicate better mobility. Based on the final score, 4 groups are defined (K1 = 15-26, K2 = 27-36, K3 = 37-42, K4 = 43-47).

  9. Change From Comparator of Functional Mobility Measured With the L-test

    Time frame: Day 1 and Day 2

    The subject starts from a sitting position. At the "Start" signal, the subject stands up from the chair, walks in a closed 10-meters L-shaped path, and sits down on the same chair. The time necessary to complete the path is measured with a stopwatch. The lower the time to complete the path, the higher the functional mobility.

Secondary outcomes

  1. Change From Comparator of Usability of the Prosthesis Foot

    Time frame: Day 1 and Day 2

    Usability is measured with an ad hoc custom-made 6-items questionnaire. Each item ranges 1 to 5. To compute the final score, each item is summed up (total range: 6-30). The higher the score, the better the usability.

Sponsors and collaborators

Lead sponsor

Istituto Nazionale Assicurazione contro gli Infortuni sul Lavoro

Other

Collaborators

  • Istituto di Chimica della Materia Condensata e di Tecnologie per l'Energia (CNR-ICMATE)
  • Istituto per i Polimeri Compositi e Biomateriali (CNR-IPCB)

Registry information

Official study title

Pilot Study to Assess Safety and Performances of a Energy Storing and Return (ESAR) Prosthetic Foot Made in Additive Manufacturing

Important dates

Study start
2025
Primary completion
2025
Study completion
2025
First posted
Apr 22, 2025
Registry last updated
Feb 27, 2026

OpenTrials presents study information sourced from ClinicalTrials.gov. The official registry record should be consulted for the latest information.

View the official ClinicalTrials.gov record (opens in a new tab)

This listing is for discovery and informational purposes only. It is not medical advice, does not guarantee that a study is recruiting, and does not determine eligibility. Contact the study team and a qualified healthcare professional when considering participation.

Published trials that share one or more normalized conditions with this study.