Background Prosthetics and Orthotics (P&O) education in low-income nations faces significant challenges due to the prohibitive cost and limited availability of essential training materials, particularly prosthetic components like socket adapters. This scarcity directly impedes practical skill development, forcing a reliance on theoretical instruction.

Methodology A structured methodology integrating CAD modeling (Siemens NX12), Finite Element Analysis (FEA) using Siemens NX Nastran, and Fused Deposition Modeling (FDM) with PLA filament on a Creality Ender 3 printer was employed. FEA simulations guided design refinements.

Findings Physical prototype testing confirmed outstanding results. The adapter demonstrated dimensional accuracy with less than 0.1 mm deviation using a digital Vernier caliper, crucial for interoperability. Mechanical compression testing on an Instron 5944 UTM showed the prototype withstood a maximum load of 600 N before significant deformation, far exceeding simulation needs. Furthermore, fitting and compatibility tests confirmed a seamless and secure fit with standard transtibial prosthetic components. The final print quality was visually satisfactory with minimal post-processing.

Conclusion This work validates 3D printing as a highly effective, affordable, and reproducible solution for creating functional P&O training tools. Our findings offer a significant step towards democratizing access to practical prosthetic education globally, establishing a replicable framework for developing essential, locally manufactured training aids in various engineering and medical fields.

The authors have declared no competing interest.

This study did not receive any funding.

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