Solid Freeform Fabrication to date has largely been applied in prototype fabrication or fabrication of patterns for conventional manufacturing methods. However, many opportunities exist for using SFF for manufacturing the actual product. In particular, those applications that require or can be enhanced by custom geometric design seem to be well suited for SFF techniques. In this paper we describe the design of a prosthesis socket for a below-the-knee amputee. This socket is specifically designed to provide compliance in selected areas to enhance the comfort of the wearer. Additionally, the socket contains an integrated pylon fitting that provides a structurally superior connection while also improving the comfort of the wearer. The socket was manufactured using selective laser sintering, mated to a pylon and foot, and fitted to the patient for gait analysis. The results of the analysis indicate an improved fit is possible with manufacture by SLS.The authors acknowledge the support of the Veterans Administration for partial support of this work.Mechanical Engineerin
