Design of a mass-manufacturable, passive prosthetic foot
and product line for transtibial amputees
Name
geil-ageil-smme-meche-2026-thesis.pdf
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11.47 MB
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Adobe PDF
Checksum (MD5)
ea9417a6af0a3649c725b7c2bcad1a9b
Author(s)
Geil, Autumn R. L.
Advisor(s)
Winter, Amos G.
Date Issued
February 2026
Publisher
Massachusetts Institute of Technology
Abstract
High-activity amputees in low- and middle-income countries (LMIC) have an unmet need for suitable prosthetic feet. This paper discusses the design and validation of an injection-moldable energy storage and return (ESR) prosthetic foot, the Rugged Elastic Active (REActiv) foot, then recommends an associated product line. The Lower Leg Trajectory Error (LLTE) Design Framework is a novel framework for designing prosthetic feet that enable near able-bodied leg motion, which has successfully produced high-performance feet for below-knee amputees. This work updated the LLTE framework to accommodate stakeholder-driven design changes, including a split keel with c-channels, a sandal toe slot, a polyurethane overmold, and a ruggedized rubber sole. The new design for the REActiv foot was physically realized and underwent mechanical testing, validating that it performs as predicted. The REActiv foot also met the fatigue and strength requirements of international standard ISO 10328. An additional REActiv foot sample achieved 4 million step cycles with minimal deformation, indicating that the average amputee could wear the foot for over 6 years. Finally, a quantitative framework for developing prosthetic foot product lines is presented. Three case studies for different product line strategies are discussed. A product line of 4 length sizes with 2 stiffnesses per length is recommended for best biomechanical performance; a product line of 7 length sizes with 1 stiffness per length is recommended for easiest integration with existing product lines for conventional prosthetic feet. The REActiv foot is posed to fill a gap in LMIC markets for low-cost, high-performance ESR prosthetic feet. This affordable ESR option enables near able-bodied walking, preserving users’ joint health and enabling social reintegration in the face of disability stigmas.
MIT Department
Massachusetts Institute of Technology. Department of Mechanical Engineering
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