Fusion 360 • Generative Design • Carbon Fiber • FDM
This project was part of a multidisciplinary capstone focused on creating affordable, lightweight, and durable upper-limb prosthetics using 3D printing. The inspiration came from a real need in the medical field: conventional prosthetics are often prohibitively expensive and too heavy for comfortable daily use — especially for children and older adults.
We began by exploring common limitations in existing designs, particularly in terms of material weight, customization complexity, and long-term usability. After researching alternatives, carbon fiber emerged as the most promising material for our needs, offering an excellent strength-to-weight ratio and thermal resistance.
Using Autodesk Fusion 360 and its generative design features, we modeled the prosthetic arm with structural constraints in mind. We set parameters such as a maximum applied force of 1000N and a minimum allowable mass of 1500g. The software simulated dozens of design iterations, each balancing structural integrity with material efficiency.
After analyzing the results, we selected the most optimized model that delivered strength, comfort, and cost-effectiveness — all while being manufacturable using Fused Deposition Modeling (FDM). The iterative process allowed us to push the boundaries of form and function, delivering a prosthetic arm that could be both affordable and robust.
What set this project apart was not just the technical solution, but its focus on real-world usability. The final product was designed with adaptability in mind, making it ideal for users who require frequent updates due to growth, wear, or lifestyle changes.
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