Customizable suspension liner, system, and method for making the same

A suspension liner for a prosthetic system including a socket, the suspension liner arranged to custom-fit to a contour or shape of a residual limb, the suspension liner comprising:

• an inner layer arranged in shape to follow the contour of the residual limb, the inner layer forming an inner periphery of the suspension liner;
• an outer layer forming an outer periphery of the suspension liner, the outer periphery defining a shape different from a shape of the inner periphery;
• a middle layer extending between the inner and outer layers, the middle layer defining a variable thickness between proximal and distal end regions of the liner to accommodate the different shapes of the inner and outer layers of the suspension liner;
• a casting core disposed in the middle layer, the middle layer including the casting core and a moldable material.

A prosthetic system including a suspension liner and a socket, the suspension liner arranged to custom-fit to a contour or shape of a residual limb, the suspension liner comprising:

• an inner layer arranged in shape to follow the contour of the residual limb, the inner layer forming an inner periphery of the suspension liner;
• an outer layer forming an outer periphery of the suspension liner, the outer periphery defining a shape different from a shape of the inner periphery;
• a middle layer extending between the inner and outer layers, the middle layer defining a variable thickness between proximal and distal regions of the liner to accommodate the different shapes of the inner and outer layers of the suspension liner;
• wherein the outer periphery corresponds in shape to a socket inner contour of a socket, the socket defining a substantially uniform or entirety uniform thickness between the socket inner contour and a socket outer contour at least between proximal and distal regions of the socket.