ESCUELA TÉCNICA SUPERIOR DE INGENIERÍA

(ICAI)
GRADO EN INGENIERÍA ELECTROMECÁNICA
Especialidad Mecánica

DESIGN OF A HAND PROSTHESIS WITH

A 3D PRINTER

Autor: Alberto Carralero Moya

Director: Kevin Fite

Madrid
July 2016
ESCUELA TÉCNICA SUPERIOR DE INGENIERÍA (ICAI)
GRADO EN INGENIERÍA ELECTROMECÁNICA
Especialidad Mecánica

DESIGN OF A HAND PROSTHESIS WITH A

3D PRINTER

Autor: Alberto Carralero Moya

Director: Kevin Fite

Madrid
July 2016
DISEÑO DE UNA PRÓTESIS DE MANO CON IMPRESORA 3D

Autor: Carralero Moya, Alberto.

Director: Fite, Kevin.

Entidad Colaboradora: Clarkson University.

RESUMEN DEL PROYECTO

Hoy en día en Estados Unidos, uno de los principales problemas en su sociedad es la sanidad, ya
que la mayoría de la gente no tiene seguro médico y sólo los más ricos pueden permitírselo.
Debido a ello, se buscan técnicas alternativas para resolver problemas con un coste mucho
menor.

Este proyecto se basa en el diseño de una prótesis de dedos y mano para personas que los hayan
perdido ya sea por nacimiento, enfermedad o accidente. El coste de una prótesis que requiera
cirugía y un tratamiento médico puede costar entre $40,000 y $100,000, cantidad que la mayoría
de personas hoy en día no puede permitirse. Por esto, cada vez más se desarrollan sistemas
alternativos que minimizan este coste, llegando en algunos casos a precios entre $50 y $100.

Uno de los sistemas alternativos más usados y el usado en este proyecto es el desarrollo de
prótesis impresas con una impresora 3D. En este proyecto, se diseñará la prótesis de la mano
excluyendo el diseño del pulgar, el cual será objeto de otro proyecto. El diseño se hace usando el
programa de diseño 3D PTC CREO Parametric. Una vez los diseños están terminados se usa una
impresora 3D llamada MakerBot Replicator 2x para la impresión de las piezas.

Los materiales usados son ABS Plastic, es la parte dura que se usará para dar consistencia a los
dedos ya que tiene alta resistencia de impacto y ductilidad. El otro material usado es el
NinjaFlex, un material muy elástico (660% de alargamiento de rotura) con el que se conseguirá
hacer los giros de las diferentes falanges de los dedos. Para el movimiento de las falanges, un
cable de 2 mm de diámetro en tensión es introducido en el material que producira el movimiento
de los dedos.

i
El proyecto está enfocado para personas con dos tipos de lesiones. El primer caso es para
personas que debido a enfermedad o accidente no tienen mano hasta parte de los metacarpos
(mitad de la palma). Para este caso será necesario el diseño de los cuatro dedos, la palma y una
pequeña parte del brazo, dónde los cables serán tensados. Aquí, el único movimiento que puede
hacer el paciente es el de la muñeca, con el que se traspasará el giro a las falanges por medio de
los cables. El diseño del conjunto completo se muestra a continuación:

El segundo caso es para personas que no tienen dedo hasta parte de la falange proximal (falange
más cercana a la palma), pero si tienen la articulación que une esta falange con la palma que será
la que producirá el movimiento del dedo. Esta parte de falange del paciente se introduce en el
agujero de la prótesis para así promover el movimiento de ésta. Este caso es bastante más
sencillo y sólo es necesario el diseño de los dedos que les falte al paciente (en caso que sea más
de uno) y una superficie en la palma para el tensado de los cables que irá fijada a ella con una
sujeción de velcro. El prototipo del dedo es el siguiente:

ii
En este proyecto, el diseño está hecho para unas medidas medias de un adulto. Éstas cambiarán
dependiendo de las dimensiones de las comparaciones, pero son medidas representativas. Para el
diseño se asume que los dedos índice y anular tendrán la misma medida de 86 mm, el corazón
será 7 mm más grande teniendo una longitud total de 93 mm, mientras que el meñique será el
más pequeño todos con una longitud de 78 mm de largo.

Por último, se hacen unos análisis de fuerzas para así analizar las tensiones y desplazamientos de
los dedos de los dos tipos de prótesis. Como los dos diseños son parecidos y no habrá mucha
diferencia entre ellos a la hora del análisis, el análisis de desplazamiento se hace para el diseño 1
con el software CREO diferenciando los dos materiales (ABS Plastic y NinjaFlex). Se analizará
el desplazamiento máximo en mm y la deformación principal máxima. A la hora del análisis de
tensiones se analizará el diseño 2 con Solid Edge. Se estudiará las tensiones de Von Mises y la
tensión principal máxima y mínima para el material NinjaFlex, ya que Solid Edge no permite la
selección de dos materiales distintos a la hora de hacer un análisis. Se hace con este material, ya
que es el que nos interesa estudiar debido a que éste sufrirá las mayores tensiones y
desplazamientos.

En conclusión, la pérdida de una mano ya sea por accidente o enfermedad puede cambiar
totalmente la vida de una persona, privándola así de hacer cosas tan cotidianas como coger un
vaso de agua. Por ello, debido a los altos precios de las prótesis que requieren cirugía en EEUU,
este tipo de prótesis será de vital importancia para personas que no pueden permitirse gastarse
altas cantidades de dinero.

iii
iv
DESIGN OF A HAND PROSTHESIS WITH A 3D PRINTER

Author: Carralero Moya, Alberto.

Director: Fite, Kevin.

Collaborating Institution: Clarkson University.

PROJECT SUMMARY

Nowadays in the US, one of the main problems is health, because most people do not have health
insurance and only the rich can afford it. As a result, additional techniques are used to solve
problems with a much lower cost.

This project is based on the design of a prosthetic fingers and hand for people who have lost
them either by birth, illness or accident. The cost of a prosthesis requiring surgery and medical
treatment can cost between $40,000 and $100,000, an amount that most people today cannot
afford. Therefore, increasingly alternative systems that minimize this cost are developed, in some
cases at prices between $50 and $100.

One of the most used systems and the one used in this project is the development of printed
prosthesis with a 3D printer. In this project, a prosthetic hand (excluding the thumb) will be
designed. The design is done using the 3D design program PTC Creo Parametric. Once the
designs are finished, the MakerBot Replicator 2x 3D printer is used to print the different parts.

The materials used are ABS Plastic that is the hard part that will be used to give consistency to
the fingers as it has high impact resistance and ductility. The other material used is NinjaFlex, a
very elastic material (660% elongation at break) with which the rotations of the different
phalanges of the fingers are done. For the movement of the phalanges, a 2 mm diameter wire is
introduced into the material and it will produce the movement of the fingers.

The project is focused for people with two types of injuries. The first case is for people who do
not have part of the palm because of illness or accident. In this case it will be necessary the
design of the four fingers, the palm and a small part in the arm, where the cables will be
tensioned. In this case, the only movement that the patient can make is the movement of the
v
wrist, with which the rotation will be transferred to the phalanges through the wires. The design
of the complete assembly is shown below:

The second case is for people who do not have finger until part of the proximal phalange (the one
closest to the palm), but they have the joint that connects the proximal phalange with the palm;
this joint will produce the movement of the finger. This part of the phalange is inserted into the
hole of the prosthesis in order to promote its movement. This case is much easier and it is only
necessary the design of the fingers that the patient do not have (if more than one) and a surface
on the palm for tensioning the wires that will be attached with a Velcro fastener. The finger
prototype is shown below:

vi
The design is made for an average adult size. These dimensions will change depending on the
patients, but they are representative measures. For the design, it is assumed that the index and
ring fingers have the same length of 86 mm, the middle finger will be 7 mm larger having a total
length of 93 mm, while the pinky finger will be the smallest one with a length of 78 mm long.

Finally, different forces analyses are done to analyze the stresses and displacements of the
fingers of the two types of prosthesis. As the two designs of the fingers are similar and there will
not be much difference between them at the time of the analysis, the displacement analysis is
made for the design 1 with the software CREO, distinguishing between the two materials (ABS
Plastic and NinjaFlex) of the finger. The maximum displacement in mm and the maximum
principal strain are analyzed. The stress analysis is done with the second design with Solid Edge.
The Von Mises stress and maximum and minimum principal stresses for Ninja Flex material will
be studied, since Solid Edge does not allow the selection of two different materials. It is made
with this material because it is the material we are interested in, because it will suffer the highest
stresses and displacements.

In conclusion, the loss of a hand either by accident or illness can completely change a person's
life, thus depriving doing daily things as picking up a glass of water. Therefore, due to the high
prices of the prostheses that require surgery in the US, this type of prosthesis will be vital for
people who cannot afford to spend big amounts of money.

vii
viii
Acknowledgements

I would like to express my sincere gratitude to Clarkson University and especially to the
Professor Kevin Fite for giving me the opportunity to work with him in the design and
development of this project, for his continuous encouragement, help and for the patient
guidance and advices.

In addition, I would like to thank my family for the continuous support and for giving me the
opportunity to study in ICAI and to go abroad one year to the USA.

ix
x
Table of contents
1. Introduction ................................................................................................................................ 5

1.1 State of the question ............................................................................................................. 6

1.2 Motivation ............................................................................................................................. 6

1.3 Objectives .............................................................................................................................. 7

1.4 Working Methodology .......................................................................................................... 7

1.5 Resources .............................................................................................................................. 8

1.5.1 PTC CREO ........................................................................................................................ 8

1.5.2 MakerBot Replicator 2x 3D Printer ................................................................................ 8

2. Introduction to the hand .......................................................................................................... 11

2.1 Anatomy of the hand .......................................................................................................... 11

2.2 Hand Injury Statistics ........................................................................................................... 12

2.3 Cost of the Injuries .............................................................................................................. 14

2.4 3D Printed Prosthetic Hands without electric device vs. Electric prosthesis...................... 15

2.4.1 3D Printed Prosthetic Hands without electric device .................................................. 15

2.4.1.1 Enabling the future.............................................................................................. 15

2.4.1.1.1 Raptor Reloaded ....................................................................................... 15

2.4.1.1.2 Unlimbited Arm......................................................................................... 15

2.4.1.1.3 K-1 Hand .................................................................................................... 15

2.4.1.2 Robohand ............................................................................................................ 15

2.4.2 Electric prosthesis ......................................................................................................... 17

2.4.2.1 Open Hand Project - Dextrus ............................................................................... 17

2.4.2.2 Myoelectric prosthesis ......................................................................................... 17

1
3. Prosthesis information .............................................................................................................. 21

3.1 Description of the people involved ..................................................................................... 21

3.2 Operation of the wires ........................................................................................................ 23

3.3 Materials ............................................................................................................................. 24

3.3.1 ABS Plastic..................................................................................................................... 24

3.3.1.1 Advantages ............................................................................................................ 24

3.3.1.2 ABS Properties....................................................................................................... 24

3.3.2 Ninja Flex ...................................................................................................................... 26

3.3.2.1 Advantages ............................................................................................................ 26

3.3.2.2 Ninja Flex Properties .............................................................................................. 26

4. Prosthesis design ...................................................................................................................... 29

4.1 Finger prosthesis process .................................................................................................... 29

4.2 Prosthesis 1 ......................................................................................................................... 31

4.2.1 Fingers........................................................................................................................... 31

4.2.1.1 Size of the fingers .................................................................................................. 34

4.2.2 Palm .............................................................................................................................. 35

4.2.3 Arm ............................................................................................................................... 38

4.2.4 Pins................................................................................................................................ 41

4.3 Prosthesis 2 ......................................................................................................................... 43

4.3.1 Finger ............................................................................................................................ 43

4.3.2 Wire surface.................................................................................................................. 46

5. Force Analysis............................................................................................................................ 49

5.1 Stress analysis...................................................................................................................... 49

5.1.1 10N in the distal phalange analysis .............................................................................. 49

2
 5.1.2 10 N in distal and middle phalange analysis ................................................................ 52

5.2 Displacement analysis ......................................................................................................... 54

5.2.1 10N in the distal phalange analysis .............................................................................. 54

5.2.2 10N in the distal and middle phalange analysis ........................................................... 56

6. Annex A - Figures in 3D ............................................................................................................. 59

6.1 Prosthesis 1 ......................................................................................................................... 60

6.1.1 Finger ............................................................................................................................ 60

6.1.1.1 First design ............................................................................................................. 60

6.1.1.2 Second design ........................................................................................................ 60

6.1.1.3 Final design ............................................................................................................ 60

6.1.2 Palm .............................................................................................................................. 63

6.1.3 Arm ............................................................................................................................... 64

6.1.4 Hand Assembly ............................................................................................................. 65

6.1.4.1 Back view ............................................................................................................... 65

6.1.4.2 Top view ................................................................................................................. 65

6.2 Prosthesis 2 ......................................................................................................................... 67

6.2.1 Finger ............................................................................................................................ 67

6.2.2 Wire surface.................................................................................................................. 68

7. Annex B - Dimensional drawings .............................................................................................. 69

7.1 Prosthesis 1 ......................................................................................................................... 71

7.1.1 Index and ring fingers – Elastic part ............................................................................. 71

7.1.2 Index and ring fingers – Hard part ............................................................................... 73

7.1.3 Medium finger – Elastic part ....................................................................................... 75

7.1.4 Medium finger – Hard part ........................................................................................... 77

3
 7.1.5 Pinky finger – Elastic part ............................................................................................. 79

7.1.6 Pinky finger – Hard part ................................................................................................ 81

7.1.7 Palm .............................................................................................................................. 83

7.1.8 Arm ............................................................................................................................... 85

7.1.9 Binding post .................................................................................................................. 87

7.2 Prosthesis 2 ......................................................................................................................... 89

7.2.1 Hard Part ....................................................................................................................... 89

7.2.2 Elastic part .................................................................................................................... 91

7.2.3 Wire surface.................................................................................................................. 93

8. References ................................................................................................................................ 95

4
1. Introduction
Hand injuries, including amputations of fingers, are surprisingly common. According to the
Centers for Disease Control and Prevention's National Center for Injury Prevention and Control,
about 41,000 people a year suffer non-fatal injuries that lead to amputations of one or more
fingers.

More than 75 percent of the injuries happen because of trauma caused by accidents. They
affect mostly young children and men older than 55. For the young ones, the injury comes 73
percent of the time from fingers being slammed in doors. For older men, power tools account
for almost half of the amputation accidents.

As advanced prosthesis can cost up to $40,000, and many cannot afford this technology.
Additive manufacturing technology offers the potential for inexpensive custom prosthesis
designs that can be fabricated with standard desktop 3D printers.

A person with a hand injury normally has a consultation with a prosthetics expert after the
amputation is complete. Needs are assessed and options are provided. Some people might
want more than one prosthesis, perhaps one for the most natural cosmetic appearance and
another for functionality. The prosthesis involved in this project is the functionality one.

This prosthesis operates with a pad that is strapped with Velcro to the user´s hand and wrist.
Wires run from the pad up through the fingers, and movement of his fingers at the joint where
they connect with the palm actuates the device. The big problem of this prosthesis is that you
cannot pick up tiny objects, like a dime, but that has been the only drawback.

So the main objective of the project is the development of a hand prosthesis, in particular the
four fingers (without the thumb) and the movements of the distal and proximal interphalangeal
joints. This project is designed for people who were born missing fingers or who have lost them
due to disease or natural disaster. [1]

5
1.1 State of the question
Over recent years the field of prosthetic hands has received increased attention.
Anthropomorphic characteristics (e.g. appearance, kinematics), use of light-weight, low-cost
and flexible materials are some of the current trends. This is due to the prosthetic hands being
able to be used for a number of everyday life applications, ranging from teleoperation studies,
to human robot interaction, for humanoid robots or even as affordable myoelectric prostheses.

The prosthetic hands are created with different levels of anthropomorphism. So the design
directions will be provided for prosthetic hands that have only anthropomorphic fingers and/or
humanlike placement of the finger base frames (simple low-cost robot hands), as well as for
anthropomorphic myoelectric prostheses, inspired by the most dexterous end-effector known,
the human hand.

There are many different types of diseases in the hands, but this project is based around people
that do not have fingers whilst still having the metacarpo-phalangeal joint that allows bending
the joint between the palm and the proximal phalange. [2]

1.2 Motivation
Firstly, one of the most important motivations of this project is helping people that do not have
access to many resources because the prosthesis is made with plastic and the use of it does not
require any clinical or surgical intevention, which would be much more expensive.

Secondly, another reason why I am carrying out this project is due to one of my favorite
sections in the engineering being 3D modelling. This project is based with the use of 3D
modelling software and a 3D printer where you are able to have a physical view of the model
rather than purely on a computer screen.

Finally, the last reason is because I have always been interested in science and innovation and
this project is a good mix between these two sectors.

6
1.3 Objectives
The main objective of this project is to design finger prosthesis for people who were born
missing any finger or who have lost them because of a disease or an accident. Due to this
method does not requiring surgery; the people involved in this project can move the joint
between the palm and the proximal phalange (metacarpo-phalangeal joint).

The design is done for a random size, so when someone needs the prosthesis, his/her hand will
be measured and the design model will be scaled accordingly prior to fabrication

1.4 Working Methodology

For the design of the prosthesis, the designing software 3D PTD CREO Parametric is used. Once
all of the different parts of the assembly are made, these are printed with a 3D printer.

Firstly, the movements of the fingers respect to the palm were studied and after that the
fingers could be designed. The finger is designed in just one part but with two different
materials. The first material is a high strength plastic to make resistance to the finger and the
second one is an elastic plastic. With this plastic, the movements in the distal and proximal
interphalangeal joints can be designed.

All these procedures were designed with wires that are in between the distal, middle and
proximal phalanges. The flexible material at each joint allows the person that has the prosthesis
to bend the distal and proximal interphalangeal joints when he or she moves the metacarpo-
phalangeal joints.

Not every finger has the same size; the index and the ring fingers have the same size, but the
middle finger is bigger than these and finally the pinky is the smallest one.

Once the finger is completed, the next step is to link the finger with the palm. These two parts
are linked with a finger snap pin, and between this and the two parts, a cylinder made of
another material is introduced to minimize the friction.

7
1.5 Resources
The two main resources used are:

1.5.1 PTC CREO: Design software supporting product design for discrete manufacturers.
It has different sections for 3D CAD parametric feature solid modeling, 3D direct
modelling, 2D orthographic views, Finite Element Analysis and simulation, schematic
design, technical illustrations, and viewing and visualization.
This software competes directly with CATIA, Solid Edge and Solidworks.
The version used is CREO Parametric 3.0.
This software is used to design every part of the hand assembly.
PTC CREO is also used to do temperature analysis and simulation of forces applied in the
palm and fingers.

1.5.2 MakerBot Replicator 2x 3D Printer: This printer makes solid, three dimensional
objects out of melted Filament. The 3D design files are converted from CREO to Catia
(.stl files) and the 3D printer reads the files via SD card. The first step is to heat the
Filament and squeezes it out through a nozzle onto a heated surface to build a solid
object, layer by layer. This method is called Fused Filament Fabrication (FFF) [3].
The filaments used in the design are:
o Acrylonitrile Butadiene Styrene (ABS) - This material is a polymer of acrylonitrile,
butadiene and styrene. Usual compositions are about half styrene with the
balance divided between butadiene and acrylonitrile. Considerable variation is,
of course, possible resulting in many different grades of acrylonitrile butadiene
styrene with a wide range of features and applications. Acrylonitrile butadiene
styrene materials can be processed by any of the standard thermoplastic
processing methods. [4]

o Ninja Flex: It is made from a specially formulated thermoplastic polyurethane

(TPU) material. This technology boasts great flexibility with a low-tack, easy-to-
feed texture. The result is very high elastic material (1000% elongation),

8
 excellent vibration reduction, abrasion and chemical resistance. The filament
used in this project has a diameter of 1.75mm (500 grams). The print
temperature is around 230ºC and the print speed is 15mm/s to the top and
bottom layers and 25mm/s to the rest of the layers. [5]

Then, monofilament nylon wires (D=2mm) are introduced in between the finger assembly to
get the movements of the fingers. Pins are also used to make the joint between the fingers and
the palm. The function of these wires is once the person moves his/her wrist, the joints
between the palm and the proximal phalanges and the joints between the proximal, middle and
distal phalanges will move too with the extension of the wires.

To do the printed parts, all of the following properties can affect the results of the printed
parts:

 Infill (Higher infill for a stronger part)

 Shells (More shells for a stronger part)
 Print orientation, size or design
 Bot
 Material age/condition
 Any other profile adjustments [6]

Once the parts are finished, the files are converted to stl files and are saved to a memory card
that will go to the 3D printer.

9
10
2. Introduction to the hand

2.1 Anatomy of the hand

Firstly, for the design of the prosthesis, it is necessary to make a study of the anatomy of the
hand, mainly to make sure the name and function of the different phalanges that will be
described below.

In the next pictures it is possible to see the different names of the bones in the hand:

[7]

Picture 1 – Anatomy of the hand

The human hand and wrist are comprised of three different bone groups:

1. The carpals are the base of the hand and wrist, and consist of eight small bones with
differing names.

11
 2. The metacarpals are above the carpals and form the base of the fingers. In the design of
the prosthesis this part will be design in only one part that will be called palm.
3. The phalanges form the fingers. The phalanges are comprised of the proximal, middle,
and distal groups.

o Distal phalanges are the smallest phalanges and they are in the top of the finger
making a joint with the middle phalange. Their main purpose involves supporting
the sensitive flesh of the fingertip, where a high number of nerve endings are
situated. These nerve endings translate sensory feelings of touch into nerve
impulses that are transmitted back to the brain. These bones also feature apical
tufts, which are flat expansions of bone. The tufts support the fingernails on the
dorsal side of the fingers, and the fleshy pad of skin on the palmar side of the
fingers.

o Middle phalanges are in between the distal and proximal phalanges. This middle
phalanx has two joints, and allows the finger to bend in two places. The
intermediate phalanges are unique to fingers. The thumb does not possess such
a bone, as it only consists of a proximal and distal phalanx.

o Proximal phalanges are the bones that are found at the bottom of the finger.
They are named proximal because they are the closest phalanges to the
metacarpals. The patients involved in one of this project have the finger
amputated in this phalange. [8]

2.2 Hand Injury Statistics [9] [10]

 There were 186,830 nonfatal occupational injuries to hands and wrists that involved
days away from work

12
  Wrist injuries led to 15 median days away from work and hand injuries led to 5 median
days away from work

 Number of injuries to hands and wrists by nature of injury are broken down as follows:

o 30,400 sprains, strains, and tears

o 17,000 fractures

o 12,300 pain and soreness

o 6,790 bruises and contusions

Total Industry Lost Time Incidents by Body Part

 743 incidents

 Finger injuries led with 22.88% of total incidents

 Hand/Wrist injuries were 6.85% of total incidents

Total Industry Recordable Incidents by Body Part

 2,386 incidents

 Finger injuries led with 31.44% of total incidents

 Hand/Wrist injuries were 10.03% of total incidents

Total Industry Recordable Incidents by Body Part [11]

 Finger/Hand/Wrist injuries led with 40.6% of total incidents

 Of the incidents reported:

o Floorhands and derrickmen, combined, accounted for 53% of all accidents

o 36% were struck by/against

o 26% were caught in between

13
More than 3 million people in the USA have a disability in their hands and/or forearms,
including orthopedic impairments, either congenital or injury related. [12]

About one in every 2000 new born babies will have some form of a limb deficiency; it may be
absent parts of fingers or toes, complete absence of all four limbs or something in between.
Another larger group of children lose limbs in accidents, especially to lawn mowers, trains, all-
terrain vehicles, and motorcycles; or to disease, including cancer. [13]

2.3 Cost of the Injuries

Some companies will mistakenly try to save money by buying safety gloves that are lower
quality and completely inappropriate for the needs of their employees. This typically results in a
higher rate of injuries and workers who may remove their gloves because they are
uncomfortable.

On-the-job injuries are expensive and painful to your bottom line. OSHA provides a breakdown
of various occupational injuries and estimates of what they cost us per year, per incident:

 Lacerations: $40,023

 Punctures: $47,703

 Fractures: $101,833

 Crushing: $118,769 [14]

Due to this high cost, different alternatives such as the 3D plastic prosthesis are very relevant to
the U.S. amputee population.

14
2.4 3D Printed Prosthetic Hands without electric device vs. Electric prosthesis

2.4.1 3D Printed Prosthetic Hands without electric device

This kind of prosthesis appeared looking for people that cannot afford the big costs of the
electric prosthesis. The cost of a 3D printed prosthetic hand is in between $50 and $150 that
comparing it with the cost of a prosthesis that has an electric device (more than $30,000) is
nothing. There are a few associations that are designing these prostheses:

2.4.1.1 Enabling the future [15]

It is a global network of passionate volunteers using 3D printing to give the world a "Helping
Hand". This association designs different kind of plastic prosthesis without electric devices. We
can highlight these models:

 2.4.1.1.1 Raptor Reloaded: It is widely used, easy to assemble with written and video
tutorials available. The user must have a functional wrist and enough palm to push
against the device to force the fingers closed when wrist is bent.

Picture 2 – Raptor Reloaded Prosthetic Hand

 2.4.1.1.2 Unlimbited Arm: It is the most popular and easy to assemble arm design with
instructional videos and written instructions on thermoforming and assembly. The users
must have a functional elbow that bends to force the fingers closed on the hand.

15
 Picture 3 – Unlimbited Arm

 2.4.1.1.3 K-1 Hand: As the Raptor hand, users must have a functional wrist and enough
palm to push against the device to force the fingers closed when the wrist is bent. The
K-1 hand is an evolving design and is an elegant, anthropomorphic hand that utilizes
commonly available materials and 3D Printing. There is no metal hardware and all cords
are recessed for aesthetic purposes and for a better quality user experience. This hand is
intended for adults and young adults – including female veterans, teens going to prom,
or an individual going to a job interview.
The anthropomorphic design and recessed cords allow the user the option of wearing a
glove over the device.

Picture 4 – K-1 Hand

16
2.4.1.2 Robohand [16]

Robohand creates 3D printed and aluminum CNC machined, anatomically driven, custom fitted,
functional mechanical devices to help different individuals as an alternative to standard
prosthetics.

3D printing is the process of extruding layer upon layer of plastic over the same area, building
up 3D composite. Robohand make use of an online platform where you can download the free
designs for Robohand.

Robohand utilize medical grade hardware and medical splinting material to ensure the safety of
the wearer. This also enables the wearer to bath and swim with the device.

The design of Robohand uses the motion of existing joint(s) to mechanically move (or drive) the
custom made device. Robohands are not myoelectric and do not require invasive surgery. Nor
do they have motors or battery packs that add weight, require maintenance and increase cost.
They are environmentally friendly as the PLA they are 3D printed with is biodegradable.

Picture 5 – Robohand

2.4.2 Electric prosthesis

The difference between these prostheses and the ones shown above is the electric device.
These prostheses are much more expensive starting from $30,000 until $100,000. Inside this
section, there are the 3D printed prostheses and the myoelectric prostheses:

17
2.4.2.1 Open Hand Project - Dextrus [17]
The aim of the Open Hand Project is to make robotic prosthetic hands more accessible to
amputees. Leading prosthetics can cost up to $100,000. By using emerging technologies like 3D
printing, we can cut that down to a fraction of the cost which means that these devices can
reach a far broader audience

Its model is called Dextrus. It is a robotic hand that offers much of the functionality of a human
hand. It uses electric motors instead of muscles and steel cables instead of tendons. 3D printed
plastic parts work like bones and a rubber coating acts as the skin. All of these parts are
controlled by electronics to give it a natural movement that can handle all sorts of different
objects.

The hand can be connected to an existing prosthesis using a standard connector. It uses stick-
on electrodes to read signals from their remaining muscles, which can control the hand, telling
it to open or close.

This model is less expensive than the myoelectric prostheses but still much more expensive
than the prostheses without electric device.

Picture 6 – Dextrus hand

18
2.4.2.2 Myoelectric Prostheses [18]
The primary purpose of an arm prosthetic is to mimic the appearance and replace the function
of a missing limb. While a single prosthetic that achieves both a natural appearance and
extreme functionality would be ideal, most artificial limbs that exist today sacrifice some degree
of one for the other. As such, there is a wide spectrum of specialized prosthetics that range
from the purely cosmetic (which are inert) to the primarily functional (whose appearance is
obviously mechanical). Myoelectric prosthetics are an attempt to serve both purposes of an
artificial limb equally, without sacrificing appearance for functionality.

Myoelectric prosthetics have a number of advantages over body-powered prosthetics. Since it

uses a battery and electronic motors to function, the myoelectric artificial limb does not require
any unwieldy straps or harnesses to function. Instead, it is custom made to fit and attach to the
remaining limb (whether above the elbow or below) with maximum suspension using suction
technology. Once it is attached, the prosthetic uses electronic sensors to detect minute muscle,
nerve, and EMG activity. It then translates this muscle activity (as triggered by the user) into
information that its electric motors use to control the artificial limbs movements. The end
result is that the artificial limb moves much like a natural limb, according the mental stimulus of
the user.

The primary disadvantages of this kind of prosthetic are currently their weight and cost.

Picture 7 – Myoelectric hand [19]

19
20
3. Prosthesis information

3.1 Description of the people involved

There are two different people that will use this kind of prosthesis:

1. The first case is people that, due to an accident or a disease, have lost the fingers
(phalanges) and a part of the palm (metacarpus). In this case, the joints between the
palm and the proximal phalanges are needed and will be designed with a pin in between
the two parts. An example of a person that can use this prosthesis is a person that had a
traffic accident and he lost part of his hand until the metacarpus as it is shown in the
next figure, assuming that this person lost his fingers until where the metacarpal
fractures are shown:

Picture 8 – Metacarpal fractures

2. In this case the patient just missed the fingers until part of the proximal phalange, so the
joints between the proximal phalanges and the palm are not needed, and it is only
needed the joints between the distal, middle and proximal phalanges will be designed
with a flexible material. This prosthesis is much more simple because the movement of
the wrist is not needed due to the patient can move the proximal phalange. So for this

21
case the palm and the arm part are not needed because the movement of the finger will
occur when the patient moves the distal phalange. An example of the prosthesis of this
case is shown below:

[20]
Picture 9 – Prosthesis 2 example

Then, this prosthesis is fastened across with a strap of textile material with a Velcro-
type fastening, shown in the next picture:

[1]
Picture 10 – Velcro-type fastening

22
The first step to start with the prosthesis is making a plaster hand with exactly the same
anatomical features of the person involved.

3.2 Operation of the wires

For this section, the two cases are explained separated:

1. The first case is when the person does not have until part of the metacarpus. In this case
the person can only move the wrist. So once he/she moves it, the pin joint between the
palm and the proximal phalanges and the flexible joints between the proximal, medium
and distal phalanges move immediately because the wire is extended, so that means
that the next joints have to rotate. The big problem of this prosthesis is as the person
can only do one movement (wrist movement); all the joints and all the fingers will rotate
at the same time. So if one finger rotates, the rest will rotate too.

2. The mechanism in the second case is much easier because now as the person has part of
the proximal phalange, the joint between the palm and the proximal phalange is not
needed. Now, he/she can move each finger separately and if he/she moves one finger,
this does not mean that the rest of the fingers have to move too as in the first case. In
this case, the prosthesis has a hole in the proximal phalange that has the same
measures than the part of the proximal phalange of the person has. This process starts
when the person moves the proximal phalange of one of his/her finger, this means that
the flexible joints between the proximal and medium, and medium and distal phalanges.

In both cases the wires have to be tensioned because when the person moves the wrist in the
first case and the proximal phalange in the second case, if the wires are not taut the joints will
not rotate.

23
3.3 Materials

3.3.1 ABS Plastic

The 3D Printer MakerBot Replicator 2x can print in ABS (acrylonitrile butadiene styrene)
thermoplastic and is the primary material used by the UP family of 3D printers. ABS is the
plastic of choice for 3D Printers, as the printed parts are tough and durable. The parts are built
tough and can be used as usable, functional end-use parts and it is the same plastic as
Lego. Removal of support material is easy and safe. No dangerous chemicals are required; just
simply break away the support that is printed in the same material but in a lower density. You
can slice your models into parts, print them in components and then just glue using nail varnish
remover (Acetone). [21]

ABS is tough and somewhat flexible. ABS becomes softer with increased temperatures, but at
the extrusion temperatures used in a MakerBot it remains fairly viscous. That means that ABS
melts quickly inside the extruder but doesn’t drip during travel moves. ABS can also withstand
heat well enough that we use it to make the plastic components of the Replicator 2X’s
extruders.

Properties of ABS plastic: High strength, impact resistance, toughness, heat resistance, good
electrical insulator, moisture resistant, high strength to weight ratio. ABS is tough and strong
over the recommended temperature range of -30°C to +60°C.

3.3.1.1 Advantages [22]

 High impact strength and ductility, which combine to give exceptional

toughness.
 Good chemical resistance.
 Abrasion resistance.
 High strength solvent welds jointing which allows efficient system assembly and
modification.
 Rubber Ring jointing methods, allowing compatible systems jointing techniques.
 Nontoxic and non-taint properties.

24
  Withstands aggressive ground waters.
 High strain tolerance for buried applications.
 Good resistance to ultraviolet light.
 Lower celerity and extreme tolerance to water hammer surges.

3.3.1.2 ABS Properties [6] [23] [4]

General Properties Imperial Metric

Specific gravity 1.04 / 1.04 /
Moisture Absorption – 24h 0.19 % 0.19 %

Table 1 – ABS Plastic General Properties

Mechanical Properties Imperial Metric

Tensile Strength, Yield 6100 psi 42 MPa
Tensile Strength, Ultimate 5000 psi 34 MPa
Tensile Modulus 310000 psi 2140 MPa
Impact Strength Standard 5.7 ∗ / 31 Kg
Impact Strength Maximum 6.2 ∗ / 33.75 Kg
Compressive Strength 1100 psi 7.58 MPa
Standard
Compressive Strength 7100 psi 48.95 Pa
Maximum
Flexural Strength Standard 8970 psi 61.85 MPa
Flexural Strength Maximum 13731 psi 94.67 MPa
Elongation at Yield 3% 3%
Elongation at Break 30% 30%
Hardness-Rockwell R105 R105
Table 2 – ABS Plastic Mechanical Properties

25
 Thermal Properties Imperial Metric
Melting Point 392 ºF 200 ºC
Glass Transition 221 ºF 105 ºC
Heat Deflection Temp @ 264 203 ºF 95 ºC
psi/ 18 MPa
Heat Deflection Temp @ 66 214 ºF 101 ºC
psi/0.45 MPa

Table 2 – ABS Plastic Thermal Properties

3.3.2 Ninja Flex

Ninja Flex flexible filament leads the industry thanks to its superior flexibility and longevity
compared to non-polyurethane materials. Its consistency in diameter and roundness outpaces
other polyurethane materials. It is made from a specially formulated thermoplastic
polyurethane (TPU) material. The result is uniquely flexible, strong prints ideal for direct-drive
extruders that will be very useful for the design of the fingers.

Very flexible, it is almost silicone-like. It stretches, bends, twists and folds without deforming
the printed objects original shape. Sturdy enough to hold its own shape and doesn’t flop over
with a minimum wall thickness of 2mm. [24]

The printed guidelines are shown below:

 Extruder Temperature: 225°C – 235°C

 Black requires 225°C for proper adhesion.

 1.75mm filament spool = .50 kg

 Platform Temperature: 40ºC

26
  Print Speed:
o Top and bottom layers: 10-20 mm/s (600-1200 mm/min)
o Infill speeds for complex parts: 15-35 mm/s (900-2100 mm/min)
o Simple parts with direct drives can print faster between 60-80 mm/s

3.3.2.1 Advantages
 Truly flexible (no fill or layer manipulation required to achieve performance)
 1000% elongation allows for repeated movement and impact without wear or
cracking
 Excellent build platform adhesion and bonding between layers
 Polyurethane composition allows for excellent vibration reduction
 Patented low friction exterior allows for smooth feeding
 Abrasion resistance 20% better than ABS and 68% better than PLA plastics
 Consistent diameter and material properties providing reliable, high quality prints
 Chemical resistant to many industrial materials
 Adheres to all standard build platforms without glue/tape
 Shore Hardness = 85A

3.3.2.2 Ninja Flex Properties [25]

General Properties Imperial Metric

Specific gravity 1.19 / 1.19 /
Moisture Absorption – 24h 0.22% 0.22%

Table 4 – Ninja Flex General Properties

Mechanical Properties Imperial Metric

Tensile Strength, Yield 580 psi 4 MPa
Tensile Strength, Ultimate 3700 psi 26 MPa
Tensile Modulus 1800 psi 12 MPa

27
 Elongation at Yield 65% 65%
Elongation at Break 660% 660%
Toughness 12000 ∗ / 82.7 ∗ / ∗ 10
Hardness 85 Shore A 85 Shore A
Impact Strength (23ºC) 2 ∗ / 4.2 /
Abrasion Resistance 0.08 mg 0.08 mg

Table 5 – Ninja Flex Mechanical Properties

Thermal Properties Imperial Metric

Melting Point 420 ºF 216 ºC
Glass Transition -31 ºF -35 ºC
Heat Deflection Temp @ 140 ºF 60 ºC
10.75 psi/0.07 MPa
Heat Deflection Temp @ 66 111 ºF 44 ºC
psi/0.45 MPa

Table 6 – Ninja Flex Thermal Properties

The most important property of the Ninja Flex is the elongation at break that is 660%.
Comparing this with the elongation at break of the ABS plastic (around 30%), it is possible to
see the big difference between them. Due to this property, the finger will rotate by mechanical
deformation of the Ninja Flex joints.

28
4. Prosthesis design

4.1 Finger prosthesis process

Initial models of the fingers did not have the flexible material, so the finger was designed in
three different parts (distal, intermediate and proximal phalanges). These three different parts
were linked with a pin in between each of the two phalanges and one in between the proximal
phalange and the palm. So every finger had three pins. The problem was that the joints were
not perfect so the mechanism did not work very well. The 3D design of this model is shown
below:

Figure 1 – First design of the finger

The next step was the design of the distal and intermediate phalanges in only one part to
minimize the problem shown in the first design. Thereby, the model was not theoretically as
good as the first model because the joint between the distal and intermediate phalange was
fixed. The big advantage was that the mechanism of the wires worked much better in this case

29
than in the first design. However, the problem with the pin between the medium and proximal
phalange was the same as in the first design.

Figure 2 – Second design of the finger

As the prosthesis with the pins did not work very well, other alternatives were investigated and
it was discovered that the 3D printer can print with a very elastic material (ninja flex). This
material does the same function as the pins, so now the finger is only one part but with two
different materials and the joints can rotate due to the flexible material. With this design, only
the pin that connects the finger with the palm is needed.

Figure 3 – Final design of the finger

30
4.2 Prosthesis 1
The first case is when the patient does not have until part of the metacarpus. In this case the
person can only move the wrist, so the design of this prosthesis has a few different parts shown
below:

4.2.1 Fingers
The fingers are the main part of the prosthesis. The ring and the index fingers will have
the same size. The middle finger will be bigger than them and the pinky is the smallest
one. The different sizes are shown in the dimensional drawings at the end of the report.
The design of the finger is based in using different materials. The prosthesis of the finger
is divided in two main parts:

 The first part is done with a flexible material called Ninja Flex. Its function is to
rotate the joints between the distal and medium phalanges, and between
medium and proximal phalanges.

Figure 4 – Flexible part of the finger

 The second part is done with ABS plastic, a hard plastic and its function is to give
structural integrity to the finger. At the beginning, the end of this part (the part
that is joint with the palm was designed with the elastic material, but it did not
work very well with the pin that is in between the fingers and the palm. So, the
final design includes this part done with ABS plastic.

31
 The hole shown below in the top of the finger is designed to make a knot to fix
the wire with the finger.

Figure 5 – Hard part of the finger

These two parts are designed with holes inside them that are shown with the light lines
in the figures above. Inside them, the wire is introduced to produce the movement
when the patient moves the proximal phalange in one case or the wrist in the other one.

As the finger is created with two different materials, it is necessary to design something
to join these parts. So as it is possible to see in the wireframe pictures shown below,
three holes with two different sections are created in the hard part to keep the elastic
and hard part together and avoid that they can separate. In the other case, the hard
part is designed with the parts that have the same size as the holes to fix with them.

Figure 6 – Prosthesis 1 finger (Visible and hidden edges view)

So the final model of the finger shown in isometric view is shown below:

32
 Figure 7 – Prosthesis 1 finger (Shaded view)

In the wireframe 3D view with hidden lines lighter, it is possible to appreciate the holes
of the wires and the sections to fix the elastic and hard part:

Figure 8 – Prosthesis 1 finger (Wire frame view)

33
4.2.1.1 Size of the fingers
There are three different sizes for the fingers. It is not possible to make them with the
command `scale´ because the pin that makes the joint with the palm is the same and
the hole in each finger has to be designed with the same diameter that is the diameter
of the pin.

For the design of the finger, the measures of an adult man are taken. These measures
are relative and can change depending on the person.

Firstly, the index and the ring fingers have the same size. The length of these fingers is
102 mm including the part of the finger that is inside the palm. This part is 16 mm for all
the fingers. So the real length of the finger is 86 mm.

Secondly, the medium finger is longer than the index and ring fingers. The difference
between them is mainly in the medium phalange, the difference here is 6 mm and there
is a small difference in the proximal phalange of 1 mm. So the medium finger is 7 mm
bigger than the other two. The total length is 109 mm and the real length is 93 mm.

Thirdly, the pinky is the smallest one. Now the difference is mainly in the proximal
phalange that is 4 mm smaller than the index. There is also a difference in the parts that
join the phalanges. In the rest of the fingers, this distance is 7 mm, but in the case of the
finger is 5 mm in each joint, so the difference in the joints will be 4 mm. In conclusion,
the pinky is 8 mm smaller than the index. Its total length is 94 mm and the real length is
78 mm.

The difference on the length of the fingers is shown below where the finger on the left is
the index and the one on the right is the pinky. The width of the fingers is the same for
the four fingers.

34
 Figure 9 – Fingers size (Shaded view)

4.2.2 Palm
The second part is the palm. Its function is to guide the wires to the arm. In the top of
the palm a 3 inches pin is introduced to make the joint between the fingers and the
palm. In the bottom, there are two small 0.3 inches pins that make the joints between
the palm and the arm.
The next picture shows the side view where the fingers are introduced. The main
objective is to see how the wires go from the fingers to the palm going inside the 4 small
circles shown in the view.

35
At the bottom of this view, it is possible to see a fifth hole that is designed in case the
patient will also need the thumb.

Figure 10 – Front of the Palm (Visible and hidden edges view)

In the top view, it is appreciated how the wires go through the palm, starting at the end
of the fingers as it is said before and ending in the arm.
It is also important to notice that two parallelograms are designed in the top of the palm
to fix the wires with the palm. In the figure it is shown because the lines are lighter
when they go through these parallelograms.

Figure 11 – Top of the Palm (Visible and hidden edges view)

36
The last view of the palm shows the diameter of the pins that make the joints between the
fingers and the palm and between the arm and the palm. This diameter is 5 mm. So
converting this number to inches, the pins bought are 13/64’’ that is 5 mm.

It is also shown the wide of the two parallelograms mentioned before.

Figure 12 – Side of the Palm (Visible and hidden edges view)

The isometric view of the final palm model is shown below:

Figure 13 –Palm (Shaded view)

37
In the wireframe 3D view with hidden lines lighter, it is possible to appreciate the holes
of the wires:

Figure 14 –Palm (Visible and hidden edges view)

4.2.3 Arm
The third part is the arm. Its function is to fix and tense the wires. This part is mandatory
because when the patient moves the wrist, the wires will stretch causing the movement
of the phalanges.
To tense the wires there are two options. The first one is to make a knot at the end of
these four circles. The second one and the best one is to introduce the wires in small
aluminum cylinders with a diameter a little bit bigger than the holes (5mm). The
function of the cylinders is to tense the wires to make sure the operation of the wires.
The arm of the patient is introduced in this part fixing the part with the arm. It is fixed
with a Velcro strap at the end of the part.

38
 Figure 15 – Front of the Arm (Visible and hidden edges view)

The next picture shows the length of the arm part. On the left, it is possible to see the 5
mm hole where the pins are introduced to join the arm with the palm.
The Velcro strap is designed to go at the right of the part (end of the arm).

Figure 16 – Side of the Palm (Visible and hidden edges view)

The final model of the palm shown in isometric view is shown below:

39
 Figure 17 –Palm (Shaded view)

In the wireframe 3D view with hidden lines lighter, it is possible to appreciate the holes of
the wires:

Figure 18 –Palm (Visible and hidden edges view)

40
 4.2.4 Pins
The fourth part is the pin that makes the joint between the fingers and the palm. The
pin is an 18-8 Stainless Steel Low-Profile Binding Post with 3" long (7,65 mm), 0.2"
diameter (5mm). The pin has a 3/8" thread depth where a fastener is inserted to attach
the palm to the fingers. The dimensional drawing of it is in the annex at the end of the
report.

[26]

Figure 19 – Pin that joins the palm with the fingers

The fifth part is the pin that makes the joint between the arm and the palm. There are
two pins with the same size. The size is 0.3" long and 0.2" diameter. The pin is the same
kind of pin that the one shown above. These two pins and the one explained in number
four are bought online in McMaster-Carr.

The final design of the hand is shown below.

The first picture shows the bottom of the part. It is appreciated the holes in the distal and
proximal phalanges where the wires will go.

41
 Figure 20 – Bottom of the hand (3D Shaded view)

This second picture shows the top of the hand. Here it is observed how the wires go out the
fingers and are introduced in the palm going through it and ending in the arm where the wires
are fixed and tensed.

Figure 21 – Bottom of the hand (3D Shaded view)

42
As the patient in this case can only move the wrist, when the patient moves it, due to the
operation of the wires that are tensed in the arm, immediately the patient will move first the
proximal phalanges, second the middle phalanges and third the distal phalanges.

The main disadvantage of this prosthesis is that the patient can only move the four fingers at
the same time and he cannot move each finger independently. However, for the basic things,
the patient will only need to move the four fingers at the same time.

4.3 Prosthesis 2

4.3.1 Finger
In the case that the patient has part of the proximal phalange, the palm and the arm are not
needed. Here, the patient will introduce the part of his proximal phalange in the hole created at
the end of the elastic part. This hole is shown in the next picture in light lines at the right of the
figure. It is also possible to see the operation of the wires. Now, it is the same as the other
prosthesis in the distal and medium phalanges. However, as in the proximal phalange there is a
hole where the patient introduces his part of the finger, the wire has to go outside the proximal
phalange before the hole. Once the wire is outside the part, it goes to a surface in the palm that
tense and fix the wire.

Figure 22 – Flexible part of the finger (Visible and hidden edges view)

43
As the distal and medium phalanges are the same as in the other prosthesis, the hard part is the
same but in this case without the last part because now the joint between the proximal
phalange and the palm is not needed. The hard part made with ABS plastic is shown below:

Figure 23 – Hard part of the finger (Visible and hidden edges view)

In the next wireframe picture it is possible to see the three holes created in the hard part to
keep the elastic and hard part together and avoid that they can separate. In the other case, the
hard part is designed with the parts that have the same size as the holes to fix with them.

Figure 24 – Prosthesis 2 Finger (Visible and hidden edges view)

44
So the final model of the finger shown in isometric view is shown below:

Figure 25 – Prosthesis 2 finger (Shaded view)

In this prosthesis, the patient introduces the part of his proximal phalange in the hole created in
the prosthesis. Then, when he or she moves this part, immediately due to the operation of the
wires, the middle phalange will move and also the distal phalange will rotate to. With this
movement the patient can hold a bottle or take something from the floor.

In the wireframe 3D view with hidden lines lighter, it is possible to appreciate the holes of the
wires and the sections to fix the elastic and hard part:

45
 Figure 26 – Prosthesis 2 finger (Visible and hidden edges view)

4.3.2 Wire surface

Then, a surface is created and is placed in the palm to tense the wires. In the next picture the
wires go from the fingers to the holes on the top of the picture and then the wires go to the
holes on the bottom where the wires are tensed. This surface is fixed to the palm with a Velcro
strap.

Figure 27 – Wire surface (Shaded view)

46
The wireframe 3D design shows the holes and it is shown below:

Figure 27 – Wire surface (Visible and hidden edges view)

47
48
5. Force Analysis
In this section, a force analysis is done with CREO and Solid Edge. As the two designs of the
fingers are very similar and the results will not have a big difference between them, the
displacement analysis is done with the prosthesis 1 with the software CREO and the stress
analysis is done with the prosthesis 2 with Solid Edge.

5.1 Stress analysis

The stress analysis is done with Solid Edge. For the simulation, in Solid Edge it is not possible to
differentiate the two materials. So as we are only interested in the small sections because when
the sections are smaller the stresses will be bigger and if the finger breaks, it will always break
in the small sections, the finger is designed with the properties of the Ninja Flex that are shown
at the beginning of the report. The next step is fixing the constraint that will be the face closer
to the palm. The last step is introducing the forces and running the simulation.

5.1.1 10N in the distal phalange analysis

For the first simulation a 10N force that simulates for example a 1 liter bottle of water. The
force will be in the back of the distal phalange.

Firstly, Von Mises stress is considered to be a safe haven for design engineers. Using this
information an engineer can say his design will fail, if the maximum value of Von Mises stress
induced in the material is more than strength of the material. It works well for most cases,
especially when the material is ductile in nature. [27]

This theory proposes that the total strain energy can be separated into two components:
the volumetric (hydrostatic) strain energy and the shape (distortion or shear) strain energy. It is
proposed that yield occurs when the distortion component exceeds that at the yield point for a
simple tensile test. This leads to a failure criteria:

49
 1− 2 + 1 − 2 + 1 − 2 >= 2 × Eq.1 [28]
2 2

In this case, the maximum Von Mises Stress is in the joint between the proximal and medium
phalanges and the value is 3.54 MPa that is lower than the yield stress of the Ninja Flex (6.89
MPa). So we can conclude that the material will not fail when a 10N force is applied in the distal
phalange.

Figure 28 – Von Mises Stress (10N in distal phalange)

As the Von Mises Stress criteria, this failure criterion predicts failure based on different
mechanisms.

According to this theory failure will occur when the maximum principal stress in a system
reaches the value of the maximum strength at elastic limit in simple tension. For the two
dimensional stress case this is obtained from the formula below:

1 1
1 = − + − 2
+4∗ 2
Eq.2 [28]
2 2

50
The Maximum Stress is shown in the next picture and as it is possible to see it will be bigger in
the top of the joint because the material is lengthened. The higher value is 3.5 MPa.

Figure 29 – Maximum Principal Stress (10N in distal phalange)

As it is studied in Mechanics of Materials, the minimum principal stress is the smallest of the
three principal stresses or eigenvalues.

It is not really related with compressive stress. The definition of compression depends on your
coordinate reference frame. If your principal stresses were 100, 50 and 0 MPa, then 0 is more
compressive than 50 or 100 MPa. But that's not a compressive stress.

So it can be seen as a compressive stress but practically, it depends on the coordinate reference
you choose.

For our analysis, the minimum principal stress value is -3.44 MPa, and the negative sign
indicates that the fibers are compressed and the stress now is a ‘compression’.

51
 Figure 30 – Minimum Principal Stress (10N in distal phalange)

5.1.2 10 N in distal and middle phalange analysis

The difference between this analysis and the one shown above is that now another 10N force is
introduced in the middle phalange. In this case, as it was foreseeable the stresses are bigger.

The Von Mises Stress has its higher value in the same place as the other analysis and its value is
4.71 MPa that it is still lower than the yield strength of the Ninja Flex so the material will not
fail.

Figure 31 – Von Mises Stress (10N in distal and middle phalanges)

52
The higher value of the Maximum Principal Stress in this case is also in the top of the joint
between the middle and proximal phalange and it is 4.65 MPa.

Figure 32 – Maximum Principal Stress (10N in distal and middle phalanges)

And the higher value (with negative sign that means ‘compression’ as it is said before) of the
Minimum Principal Stress is 4.57 MPa and it is placed in the bottom of the joint.

Figure 33 – Minimum Principal Stress (10N in distal and middle phalanges)

53
5.2 Displacement analysis
For the displacement analysis as it is said before is done with CREO. For the simulation, in CREO
it is possible to differentiate the two materials. The first step is the creation of the ABS Plastic
and the Ninja Flex with the properties shown at the beginning of the report. Once the two
materials are assigned for the two different parts, the next step is fixing the constraints. The
constraint will be the hole where the pin is introduced to fix the fingers with the palm. The last
step is introducing the forces and solving the simulation.

5.2.1 10N in the distal phalange analysis

As in the stress simulation, the first analysis is a 10 N force placed in the distal phalange.

For this simulation, the hole where the pin joins the finger with the palm is fixed. The higher
value of the displacement will be in the top of the finger because the joints will turn. This value
is around 20 mm.

Figure 34 – Displacement (10N in distal phalange)

The maximum principal stress is the maximum normal strain possible for a specific point on a
structural element. Shear strain is 0 at the orientation where principal strain occurs.

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The normal strains (ex' and ey') and the shear strain (ex'y') vary smoothly with respect to the
rotation angle, in accordance with the transformation equations given above.

There exists an angle where the shear strain ex'y' vanishes. That angle is given by:

2
tan 2 = .3
−

This angle defines the principal directions. The associated principal strains are given by:

+ −
= ± + .4
,
2 2

Where is the variable that is analyzed (maximum principal strain)

The transformation to the principal directions with their principal strains can be illustrated as:

Picture 11 - Strains in given and principal directions [29]

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So the higher value of the maximum principal strain is placed as the maximum principal strain in
the joint in between the middle and proximal phalanges. The higher value is 0.0778 [-].

Figure 35 – Maximum Principal Strain (10N in distal phalange)

5.2.2 10N in the distal and middle phalange analysis

The second analysis is the same as the stress analysis. Now another 10N force is placed in the
middle phalange and the results are shown below. In this case the maximum displacement is 25
mm that is 5 mm more than in the first analysis.

Figure 36 – Displacement (10N in distal and middle phalanges)

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In the case of the maximum principal strain the higher value is 0.1, around 25% more than in
the first case.

Figure 37 – Maximum Principal Strain (10N in distal and middle phalanges)

Note: These analyses are keeping fixed a determinate section of the fingers, but this is not
completely true because the fingers will rotate in the prosthesis 1 with the pin in between the
palm and the finger and in the prosthesis 2 with his/her real joint. So the fingers will endure
more than the forces indicated in the analysis.

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58
 6. Annex A

Figures in 3D

59
6.1 Prosthesis 1

6.1.1 Finger

6.1.1.1 First design

60
6.1.1.2 Second design

61
6.1.1.3 Final design

62
6.1.2 Palm

63
6.1.3 Arm

64
6.1.4 Hand Assembly

6.1.4.1 Back view

65
6.1.4.2 Top view

66
6.2 Prosthesis 2

6.2.1 Finger

67
6.2.2 Wire surface

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 7. Annex B

Dimensional drawings

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71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
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8. References

[1] M. Clancy, "Man creates DIY prosthetic device after amputation," The Arizona Republic, 5 August
2014.

[2] P. K. A. a. K. J. K. Minas V. Liarokapis, "Quantifying Anthropomorphism of Robot Hands".

[3] MakerBot, "Replicator 2X - Experimental 3D printer - User manual".

[4] "Prospector," [Online]. Available: https://plastics.ulprospector.com/es/generics/1/acrilonitrilo-

butadieno-estireno-abs.

[5] "Fenner Drives," [Online]. Available: http://www.fennerdrives.com/ninjatek/_/3d/?=.

[6] MakerBot, "PLA and ABS Strength Data," Brooklyn, NY 11201.

[7] Merriam-Webster, [Online]. Available: http://www.visualdictionaryonline.com/human-

being/anatomy/skeleton/hand.php.

[8] Healthline Editorial Team, "Health line," 2015 February 26. [Online]. Available:
http://www.healthline.com/human-body-maps/.

[9] "Ringer Gloves," [Online]. Available: http://www.ringersgloves.com/hand-safety-awareness/hand-

injury-statistics/.

[10] Bureau of Labor Statistics U.S. Department of Labor , "Nonfatal Occupational Industries and
Illnesses Requiring Days Away From Work," 2012.

[11] The Association Of Energy Services Companies (AESC), "Safety Statistics for the Well Service
Industry," 2013.

[12] U.S. Department of Education, "Digest of Data on Person with Disabilitities".

[13] "Faces of Adoption and National Adoption Center," [Online].

[14] "Ringers Gloves," [Online]. Available: http://www.ringersgloves.com/hand-safety-awareness/what-

does-an-injury-really-cost/.

[15] "Enabling the future," [Online]. Available: http://enablingthefuture.org/tag/3d-printed-prosthetic-

hand/.

[16] "Robohand," [Online]. Available: http://www.robohand.net/about/.

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[17] "Open Hand Project - Dextrus," [Online]. Available: http://www.openhandproject.org/.

[18] [Online]. Available: http://www.myoelectricprosthetics.com/.

[19] "Healio," [Online]. Available: http://www.healio.com/orthotics-

prosthetics/prosthetics/news/print/.

[20] "11alive," Atlanta - Holding the Powerful Accountable. [Online].

[21] "3D Printing Systems," [Online]. Available: http://3dprintingsystems.com/products/filament/.

[22] EURAPIPE ABS Material, "Xahax," [Online]. Available: http://xahax.com/subory/Spec_ABS.pdf.

[23] Test Standard, "ABS Material Data Sheet".

[24] adafruit, 23 January 2014. [Online]. Available: https://blog.adafruit.com/2014/01/23/3d-printing-

with-flexible-filament/.

[25] NinjaTek Technical Specifications, "NinjaFlex 3D Printing Filament".

[26] "Mc-MASTER-CARR," [Online]. Available: http://www.mcmaster.com/#94887a219/=125xoy7.

[27] "Learn Engineering," [Online]. Available: http://www.learnengineering.org/2012/12/what-is-von-

mises-stress.html.

[28] "Quora," 6 March 2015. [Online]. Available: https://www.quora.com/What-is-the-difference-

between-von-Mises-Stress-and-Max-Principal-Stress.

[29] "efunda," [Online]. Available:

http://www.efunda.com/formulae/solid_mechanics/mat_mechanics/plane_strain_principal.cfm.

[30] "EFUNDA," [Online]. Available:

http://www.efunda.com/formulae/solid_mechanics/mat_mechanics/plane_strain_principal.cfm.

[31] "Open Hand Project - Dextrus," [Online]. Available: http://www.openhandproject.org/.

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