Variable elastic modulus cushion disposed within a distal cup of a prosthetic socket

A method of making a distal cup of a prosthetic socket for a residual limb of a patient, the method comprising:

• fabricating a distal disk of the distal cup;
• fabricating a proximal disk of the distal cup, wherein the proximal disk comprises a cushion custom manufactured specifically for the patient, the cushion comprising:
• a total cushion volume;
• a volume of solid thermoplastic elastomer within the total cushion volume;
• a void volume within the total cushion volume;
• a first subset volume comprising a first relative thermoplastic elastomer fill volume defined by a ratio of a first solid thermoplastic elastomer volume within the first subset volume to a first total volume of the first subset volume;
• and
• a second subset volume comprising a second relative thermoplastic elastomer fill volume defined by a ratio of a second solid thermoplastic elastomer volume within the second subset volume to a second total volume of the second subset volume,
• wherein the first and second relative thermoplastic elastomer fill volumes are different from one another, and
• wherein the first and second relative thermoplastic elastomer fill volumes are selected based at least in part on at least one physical characteristic of the patient;
• and
• coupling the distal disk to the proximal disk to form the distal cup.