Augo® 3D Prints Durable Prosthetic Sockets with Ultrasint® TPU and Ultracur3D® Coat F+ on HP PA12

Advanced materials and 3D printing technology allow the Augo® socket to provide a custom-fit, lightweight, and durable prosthetic solution for trans-tibial amputees.

Using Forward AM’s Ultrasint® TPU for comfort and HP PA12 for strength, the Augo® socket offers a tailored fit that combines flexibility and durability. This design not only improves patient comfort during extended wear but also ensures long-term resilience, making it an ideal solution for daily prosthetic use.

Project Breakdown

Industry & Application
Healthcare, Orthotics

Product
Ultrasint® TPU01, Ultracur3D® Coat F+ on HP’s PA12

Partner & Technology
HP 3D Printing, MJF (5200 series)

Why Forward AM Solutions and Materials?
Forward AM and Ultrasint® TPU was chosen for its proven performance in 3D printing, offering flexibility for comfort and durability. In addition, Ultracur3D® Coat F+ was used on HP PA12 to color the socket. These materials are optimized for use with HP MJF technology, ensuring high-quality, reliable results for prosthetic applications.

Key Numbers
The Augo® socket weighs only 531 grams yet withstands 5000N (≈500kg / 1100lbs), 4X load capacity, and 1,500,000 load cycles under ISO 10328 standards.

Augo® is a digitally produced 3D printed socket developed by the Invent Medical Group. Leveraging modern technologies like 3D scanning and 3D printing, Invent Medical creates trans-tibial (TT) prosthetics that are tailored to each patient’s anatomy.

The process begins with a precise 3D scan of the patient’s limb, followed by the design customization and 3D printing of the socket by O&P specialists. This combination of 3D scanning and additive manufacturing significantly reduces production time while allowing for fully optimized fit, design, and weight.

The Augo® socket incorporates two advanced materials: Forward AM’s TPU for the soft brim and HP PA12 for the rigid body. The result is a lightweight, robust socket that prioritizes both comfort and long-term wearability.

The Challenge

Designing a 3D printed socket that is lightweight, durable, and comfortable is no small feat, especially when it’s intended for daily wear over several hours. The product must not only be comfortable but also durable enough to endure everyday activities—from running errands to standing or walking for extended periods.

Modern additive manufacturing (AM) techniques address much of the design and comfort side, thanks to advanced algorithms and the ability to create custom-fit designs in almost any shape or size. However, two main challenges arise.

The first challenge is convincing end users that additively manufactured products can match the strength and durability of traditionally made ones. While AM technology has made strides in industrial settings, it’s less familiar to consumers. Additionally, some may argue that the layer-by-layer nature of AM leads to anisotropic strength, making the products more prone to brittleness compared to those made through methods like injection molding.

The second challenge is finding the optimal combination of AM process and materials to ensure long-lasting performance. Every 3D printing process and material offers different mechanical properties, strengths, and limitations. It’s crucial to select the right combination to create products that can withstand daily wear and tear, tailored to how and where they’ll be used.

Addressing these challenges requires innovative solutions that combine advanced technology with the right materials.

The Solution

Invent Medical chose HP’s Multi Jet Fusion (MJF) technology combined with Forward AM’s advanced materials to create Augo®. This combination delivers on three core promises: “light as a feather,” “extreme strength,” and “unparalleled comfort.”

The materials used are essential to achieve these goals. Augo® utilizes Forward AM’s Ultrasint® TPU (thermoplastic polyurethane) for the socket’s soft brim, cushioning where it comes into contact with the patient’s skin. This ensures maximum comfort, especially during extended periods of use, as it reduces the risk of skin irritation and pain around pressure points.

Meanwhile, HP’s PA12 (polyamide 12, i.e., Nylon) is used for the main body of the socket. It provides a lightweight structure that weighs only 531 grams while maintaining the durability necessary for daily use. Forward AM’s Ultracur3D® Coat F+ was used to color the socket.

The Augo® socket must withstand years of regular activity—standing, walking, and even running. To ensure long-term reliability, Invent Medical submitted the socket to extensive testing under the ISO 10328 standard, which assesses the structural strength and durability of lower limb prostheses.

Under this standard, the Augo® socket was tested to withstand a safety factor of 4X, meaning it was subjected to loads four times greater than what a typical 100-kg patient would generate during walking. Following the stress tests, the socket showed no signs of plastic deformation; it retained its shape and structure even under extreme pressure.

Finally, to simulate the long-term effects of walking, the socket was put through 1,500,000 cycles of loading. This type of test mimics the repeated pressure applied during daily wear. Remarkably, there were no signs of material fatigue, demonstrating the socket’s ability to maintain its integrity over time.

The Result

Through the use of Forward AM Ultrasint® TPU and Ultracur3D® Coat F+, combined with HP MJF technology, Invent Medical has succeeded in creating a prosthetic socket that stands out in the market for its performance, comfort, and durability.

The Augo® 3D printed socket provides a lightweight solution without compromising on strength. Its ability to endure a force of 5000N—equivalent to over 500kg (≈1100lbs) of force—proves its resilience under extreme conditions. This ensures that its wearers can go about their daily lives, confident that their prosthetic will withstand everything from everyday activities to more strenuous tasks.

Client feedback has been overwhelmingly positive. Fredrik Dahll from Blatchford Ortopedi shared his experience:

“It is one of the best prosthetic sockets I have ever used. My patient was especially pleased with the proximal brim, making everything in daily life more comfortable.”

This feedback highlights the Augo® socket’s impact on real-world users, where comfort and reliability make a tangible difference in daily life.

With the combination of HP MJF technology and Forward AM Ultrasint® materials, Augo® has set a new standard in the prosthetics industry, providing patients with solutions that are not only tailored to their needs but also optimized for long-term performance.