# US 10,245,775 B2 · Method and apparatus for transferring a digital profile of a residual limb to a prosthetic socket strut

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- Number: US 10,245,775 B2
- Document ID: US10245775B2
- Status: Granted
- Kind: B2
- Application number: 14/731,163
- Filed: 2015-06-04
- Published: 2015-12-10
- Granted: 2019-04-02
- Earliest claimed: 2014-06-04
- Assignees: LIM Innovations, Inc.
- Applicants: Lim Innovations, Inc.
- Inventors: Robert Adam Geshlider; Fred S. Williams; Jesse Robert Williams; Garrett Ray Hurley; Andrew C. Pedtke
- Web page: https://patentgrep.com/patent/US10245775B2

## CPC

- B29C 51/18: Thermoforming apparatus
- B29C 51/12: of articles having inserts or reinforcements
- B29C 51/30: Moulds
- B29C 51/46: Measuring, controlling or regulating
- A61F 2240/004: Using a positive or negative model, e.g. moulds
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C)

## Abstract

Embodiments of the provided technology relate to methods, devices, and systems that drive a transfer of the digital profile of residual limb contours to a thermoplastic article such as a prosthetic socket strut. A method of reforming a thermoplastic article to assume a desired shape, such as a contour that replicates or is complementary to the contour of a body portion, may include heating a thermoplastic article to render the article malleable. The method may further include placing the thermoplastic article against a molding surface having a desired shape that replicates the portion of the body part. Next, the thermoplastic article may be pressed against the molding surface with a compliant molding press to reform at least a portion of the article into the desired shape. The reformed thermoplastic article may then be removed from the molding surface, the article retaining the desired shape after removal.

## Claims

### Claim 1

A method of reforming a thermoplastic article to assume a desired shape, the method comprising:
heating a thermoplastic article to render it malleable;
providing a field of longitudinally extending pins, each pin having an end facet at one end of the pin, the pins extending parallel to each other, the pins being relatively longitudinally positionable relative to one another;
relatively positioning the pins in the field so that end facets corresponding to at least a portion of the field of pins define a molding surface that conforms to the desired shape;
after relatively positioning the pins, pressing via a pressurized medium the malleable thermoplastic article against the pins in the field
to reform at least a portion of the thermoplastic article into the desired shape; and
separating the reformed thermoplastic article from the molding surface, wherein the reformed thermoplastic article retains the desired shape after separating from the molding surface.

### Claim 2 (depends on 1)

The method of claim 1, wherein the thermoplastic article comprises at least a portion of a medical device.

### Claim 3 (depends on 1)

The method of claim 1, wherein the thermoplastic article comprises a component of a prosthetic device.

### Claim 4 (depends on 1)

The method of claim 1, wherein the thermoplastic article comprises a strut for a prosthetic socket.

### Claim 5 (depends on 1)

The method of claim 1, wherein the body part comprises a residual limb.

### Claim 6 (depends on 1)

The method of claim 1, wherein the thermoplastic article comprises a thermoplastic-fiber composite.

### Claim 7 (depends on 6)

The method of claim 6, wherein the fiber of the thermoplastic-fiber composite comprises multiple continuous fibers.

### Claim 8 (depends on 1)

The method of claim 1, further comprising, prior to the removing step, allowing the thermoplastic article to cool sufficiently, such that the thermoplastic article retains the desired shape.

### Claim 9 (depends on 1)

The method of claim 1, further comprising, before the placing step:
acquiring digital data representing a portion of a body part; and
using the digital data to relatively position the pins so that the end facets corresponding to the least one portion of the field of pins define the molding surface that replicates the body part.

### Claim 10 (depends on 9)

The method of claim 9, wherein using the digital data comprises using a CNC machine to adjust positions of the pins.

### Claim 11 (depends on 9)

The method of claim 9, wherein using the digital data comprises moving the pins individually using a motor.

### Claim 12 (depends on 1)

The method of claim 1, wherein the desired shape replicates a portion of a body part.

### Claim 13 (depends on 1)

The method of claim 1, wherein a motor is used to move the pins.

### Claim 14

A method of reforming a thermoplastic article to assume a desired shape, the method comprising:
providing positionable pins having end facets, the end facets defining a molding surface;
heating a thermoplastic article to render it malleable;
acquiring digital data representing a portion of a body part;
using the digital data to relatively position the pins so that the molding surface defined by the end facets conforms to the desired shape that replicates the body part, wherein the pins are relatively positioned by using a CNC machine to adjust positions of the pins based on the digital data;
after relatively positioning the pins, pressing via a pressurized medium the malleable thermoplastic article against the pins
to reform at least a portion of the thermoplastic article into the desired shape; and
separating the reformed thermoplastic article from the molding surface, wherein the reformed thermoplastic article retains the desired shape after separating from the molding surface.

### Claim 15

A method of reforming a thermoplastic article to assume a desired shape, the method comprising:
providing a molding surface that is reconfigurable with a motor;
heating a thermoplastic article to render it malleable;
acquiring digital data representing a portion of a part;
using the digital data to operate the motor to configure the molding surface into the desired shape;
after configuring the molding surface, pressing via a pressurized medium the malleable thermoplastic article against the molding surface
to reform at least a portion of the thermoplastic article into the desired shape; and
separating the reformed thermoplastic article from the molding surface, wherein the reformed thermoplastic article retains the desired shape after separation from the molding surface.

### Claim 16 (depends on 15)

The method of claim 15, wherein the molding surface comprises positionable pins, and the motor moves the pins.

### Claim 17 (depends on 16)

The method of claim 16, wherein the molding surface comprises end facets of the pins.

### Claim 18 (depends on 15)

The method of claim 15, wherein the part is a human body part.