College - Author 1
College of Engineering
Department - Author 1
Biomedical Engineering Department
Degree Name - Author 1
BS in Biomedical Engineering
College - Author 2
College of Engineering
Department - Author 2
Biomedical Engineering Department
Degree - Author 2
BS in Biomedical Engineering
College - Author 3
College of Engineering
Department - Author 3
Biomedical Engineering Department
Degree - Author 3
BS in Biomedical Engineering
College - Author 4
College of Engineering
Department - Author 4
Biomedical Engineering Department
Degree - Author 4
BS in Biomedical Engineering
Date
6-2025
Primary Advisor
Iian Black, College of Engineering, Biomedical Engineering Department
Abstract/Summary
This Final Report outlines the development of a lower limb prosthetic docking and charging station to address a critical need for individuals with unilateral transfemoral amputations who use microprocessor-controlled prosthetics. This project is focused on designing and producing a secure, accessible, and aesthetically pleasing stand to store and charge prosthetic limbs overnight, targeting the lack of commercially available, functional prosthetic storage. The absence of a functional storage solution points to a failure in meaningfully addressing the human needs of prosthetics users, exacerbating user frustration through the perpetuation of issues including prosthetics falling over into inaccessible positions, and tripping hazards due to tangled charging cords. Key objectives include creating a stable, durable, accessible, and aesthetic design that integrates charging, meets user needs, and follows engineering and safety standards. Customer requirements, gathered through Quality Function Deployment (QFD) and summarized in the House of Quality (HOQ), were translated into engineering specifications, with focus on usability and system stability. High-risk specifications were prioritized for validation during testing. A flexible design process was utilized during this project, with early prototyping and user testing being prioritized. A timeline and Gantt Chart were used to guide the key deliverables, with critical milestones that included finalizing specifications, building prototypes, and conducting usability testing. This document outlines the design evolution from the initial concept, through a PVC prototype, to a nightstand inspired final prototype shaped by customer feedback, sponsor input, and team innovations. Final product functionality was demonstrated through a verification and validation process. Key test results from this process indicated statistically significant improvements in prosthetic stabilization, increasing the horizontal force required to tip over the limb from 0.124, 0.066, 0.098, and 0.068 lbf for a prosthetic oriented with the toes facing forward at 0°, 45°, 135°, and 180° of force application, respectively, to 2.846, 0.262, 0.260, and 2.964 lbf at each respective angle (p = 2 x 10-7, p = 8 x 10-5, p = 0.02, and p = 1 x 10-5, respectively). The same was demonstrated for a prosthetic leg oriented with the toes facing left or right, increasing the horizontal force to tip from 0.656 and 0.206 lbf at 0° and 180° to 3.967 and 3.906 lbf at each respective angle (p = 2 x 10-10 and p = 1 x 10-5, respectively). Further testing demonstrated stand stability and resistance to tipping under an applied combined load of 30 lbf vertically and 13 lbf horizontally, as well as a minimal stand sliding distance of 2.14 mm when bumped with a 50 lbf impulse. Through this process, this project seeks to fill a gap in prosthetic care by delivering a practical solution to improve the quality of life for powered prosthetic users.
URL: https://digitalcommons.calpoly.edu/bmedsp/225