3-D Finite Element Stress Analysis of Lower-Limb Prosthetics with Different Composite Materials

Bég, O. Anwar; Branney, Emily; Bég, Tasveer A.; Kuharat, S.; Bhatti, M.M.; Kadir, Ali; Jouri, Walid S.

doi:10.22059/jcamech.2026.421447.1937

3-D Finite Element Stress Analysis of Lower-Limb Prosthetics with Different Composite Materials

Document Type : Research Paper

Authors

O. Anwar Bég ¹

Emily Branney ²

Tasveer A. Bég ³

S. Kuharat ¹

M.M. Bhatti ⁴ ^{, 5}

Ali Kadir ¹

Walid S. Jouri ¹

¹ Multi-Physical Engineering Sciences Group (MPESG), Aeronautical and Mechanical Engineering Department, Corrosion and Coatings Lab, Room 3-08, SEE Building, University of Salford, Manchester, M54WT, UK

² PhD student (Silicon Doping For Solid State Quantum Technologies), Physics Department, SEE Building, University of Salford, Manchester, M54WT, UK. (formerly MSc Aerospace Engineering Programme)

³ Engineering Mechanics Research, Israfil House, Dickenson Rd., Manchester, M13, UK

⁴ Department of Physics, College of Science, Korea University, 145 Anam-ro, Seongbuk-gu, Seoul 02841, Republic of Korea

⁵ Material Science Innovation and Modelling (MaSIM) Research Focus Area, North-West University (Mafikeng Campus), Private Bag X2046, Mmabatho 2735, South Africa

10.22059/jcamech.2026.421447.1937

Abstract

This article studies a key area in modern biomechanical rehabilitation engineering- prosthetic design and numerical simulation. FEA stress analysis in ANSYS APDL/WORKBENCH is conducted for a robust geometry resembling a lower limb prosthetic inspired by the Sara Diogo design. A parametric study of different loading conditions is conducted to both evaluate the suitability based on the current available prosthetics, and to critically evaluate the results against pre-existing studies to check validity. Carbon fibre (395 GPa), Epoxy Carbon Woven (395 GPa) Prepreg, and E-Glass are the 3 selected composite materials based on current practice in prosthetics design. SOLIDWORKS software is deployed to create robust and commercially pragmatic 3-D prosthetic geometries. Appropriate loading conditions are imposed. Static elastic stress analysis simulations are conducted for different materials. Mesh independence tests are also conducted, and tetrahedral (pyramidal) elements are deployed. Equivalent elastic stress, equivalent elastic strain, maximum principal stress and total deformation plots are presented for all three materials. Generally, all the materials demonstrate resilience although carbon fibre, while producing the highest von-Mises stress, does not yield and retains structural integrity, with maximum stresses computed never exceeding the yield strength. This could also be said for all composites, as they do not typically have a yield strength, the von-Mises stress will also be high. The relative cost/weight benefits of the different materials are also appraised. The study provides a good foundation for future refinement to consider impact dynamic, torsional and other complex loads relevant to prosthetic and orthotic design.

Keywords

Lower-limb prosthetics

Finite element analysis

Carbon fibre

Epoxy Carbon Woven Prepreg

E-Glass

total deformation

ANSYS. 3-D stress modelling

Subjects

BioMechanics

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