Prosthetic Limb Connector

The Prosthetic Limb Connector is engineered to maintain structural integrity under simultaneous axial, torsional, and bending forces commonly encountered during gait cycles. Inadequate connectors often exhibit stress concentration at geometric transitions, leading to fatigue fractures or deformation. This design ensures consistent load transfer along the mechanical axis using contoured transitions and low-stress radius zones. Finite element models and ISO 10328 dynamic tests validate the Prosthetic Limb Connector for high-cycle loading in both lower and upper limb applications. 

Material Specification

Titanium 6Al-4V ELI (ASTM F136), Stainless Steel 316L (ASTM F138), Aluminum 7075-T6 (AMS 4050)

Dimensional Tolerance

±0.05mm (Critical Features), ±0.1mm (Overall Profile), Thickness – ±0.02mm

Surface Finish

Ra ≤0.4µm (Contact Surfaces), Ra ≤0.8µm (Non-Critical), Anodized (Optional, Ra ≤0.2µm)

Thread Specifications

±0.03mm (Hole Position), Ø2.0–5.0mm (H7 Tolerance), Countersink Angle: 82°±1°

Heat Treatment

Solution Treated & Aged (Ti, ASTM F136), Annealed (SS, ASTM F138), T6 Temper (Al, AMS 4050)

Product Description

The Prosthetic Limb Connector minimizes micromotion at the joint interface using precision-machined H7/g6 tolerance fits and dual-lock retention features. Relative movement between components generates fretting wear and instability during patient locomotion. To prevent this, the connector employs controlled surface roughness and axial pre-load mechanisms to suppress motion below 10 microns under cyclic load. Anti-rotation elements and compressive force retention ensure that the Prosthetic Limb Connector maintains joint stiffness without performance degradation over time. 

Surface Treatment

Anodized (Ti, ASTM F86), Passivated (SS, ASTM A967), Ceramic Coating (Optional, ASTM F1044)

Certification Standard

ISO 13485, FDA 510(k), ASTM F3122 (Prosthetics), ISO 22523 (Functional Requirements)

Flatness/Parallelism

Flatness ≤0.05mm/m, Parallelism ≤0.02mm, Perpendicularity ≤0.03mm

Hole Location & Diameter

±0.05mm (Hole Position), H7 Tolerance (Bore Diameter), Counterbore Depth – ±0.02mm

Inspection Method

100% CMM (±0.01mm), Thread Gauge (Go/No-Go), Visual (10x Magnification, ISO 14971), Lot Sampling (AQL 1.0)

Technical Advantages

Material incompatibility in modular assemblies often leads to galvanic reactions and localized pitting. The Prosthetic Limb Connector uses Ti-6Al-4V ELI or cobalt-chrome alloys with passive oxide layers to resist electrochemical attack. Interfaces are sealed, and all mating surfaces are electropolished to reduce surface reactivity. The Prosthetic Limb Connector is validated under ASTM F2129 and ISO 10271 protocols for prolonged exposure to sweat, saline, and sterilization cycles, eliminating failure risks due to corrosion at dissimilar metal junctions. 

The Prosthetic Limb Connector is optimized for applications requiring high torsional strength in minimal geometric volume. Prosthetic systems often demand compact profiles to preserve anatomical clearance while transmitting significant mechanical loads. Using high-strength alloy splines and internal ribs, the connector supports torque loads above 55 Nm in diameters under 25 mm. Axial cable routing is integrated without compromising the structural integrity or introducing torsional compliance in the Prosthetic Limb Connector assembly. 

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Industry Applications

Lower Limb Prosthesis Assembly

Used in transfemoral and transtibial systems to ensure stable axial load transfer and precise angular alignment under cyclic gait loading. 

Upper Limb Modular Integration

Supports mechanical and electrical coupling in elbow or wrist units, allowing compact sensor routing and joint torque transmission with minimal backlash. 

Rehabilitation Robotics Interface

Acts as a mechanical intermediary for robotic assistive limbs, maintaining consistent joint stiffness under variable motor-driven actuation and patient interaction. 

Powered Prosthetic Limb Systems

Enables secure mounting of actuated joints and battery modules, while isolating high-frequency vibration and minimizing signal interference in smart limbs. 

Custom Socket Attachment Platforms

Provides mechanical anchoring between patient-specific sockets and modular limb components, maintaining interface rigidity under repeated donning and doffing cycles. 

Pediatric Growth-Adaptable Systems

Supports modular adjustability in limb length and orientation for pediatric use, enabling precise mechanical realignment during growth phases. 

 

Prosthetic Limb Connector

Fatigue Durability Over Extended Gait Cycles

The Prosthetic Limb Connector is designed to withstand cyclic fatigue beyond 2 million loading cycles, as defined by ISO 10328 and ISO 7206 standards. Repetitive stresses during ambulation can induce micro-crack propagation in conventional connectors. This connector incorporates fatigue-resistant geometries, HIP-treated materials, and redundant load paths to ensure fail-safe performance.  

Clinical alignment correction requires angular precision with secure fixation. The Prosthetic Limb Connector features a multi-axis angular adjustment mechanism with sub-degree resolution and a post-lock positional retention system. Misalignment or rotational drift after adjustment can compromise gait mechanics. To address this, the Prosthetic Limb Connector provides <0.1° deviation during repeated articulation, confirmed by motion capture and torque-resistance testing. 

 

Prosthetic Limb Connector

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure dimensional precision in Prosthetic Limb Connector manufacturing?

Frigate uses 5-axis CNC machining with in-process coordinate measuring systems to maintain tolerances within ±5 microns on all mating features. Precision inspection protocols include laser scanning and air gauge measurements for bore concentricity and parallelism. Dimensional conformity is statistically monitored using SPC to detect process drift. This guarantees connector compatibility across modular prosthetic systems with zero axial play. 

 

What kind of mechanical locking strategies does Frigate implement in its Prosthetic Limb Connector designs?

Frigate incorporates dual-stage locking systems combining axial compression collars with indexed anti-rotation keys. These features provide mechanical redundancy and maintain positional integrity under torsional and vibrational loads. Locking performance is validated through torque-to-failure and cyclic loosening tests per ASTM F543 standards. This ensures stable joint fixation even under asymmetrical gait forces. 

 

How does Frigate validate corrosion resistance in Prosthetic Limb Connectors for long-term clinical use?

Frigate subjects all connectors to accelerated corrosion testing, including 1000-hour salt spray exposure and electrochemical impedance spectroscopy. Surface treatments are tested for pitting initiation and galvanic potential against dissimilar limb materials. Components are also evaluated post-autoclave and ethylene oxide cycles to simulate clinical sterilization. This comprehensive testing ensures biostability and mechanical integrity in real-world conditions. 

What analysis methods does Frigate use to ensure fatigue durability of Prosthetic Limb Connectors?

Frigate performs finite element analysis (FEA) under multiaxial load profiles modeled from actual gait data. Physical connectors are then tested on servo-hydraulic fatigue rigs using ISO 10328-standard cyclic bending and torsion loads. Strain gauge instrumentation and crack propagation monitoring are used to track early failure indicators. Fatigue thresholds exceed 2 million cycles with no structural compromise. 

 

How does Frigate handle integration of signal pathways within load-bearing Prosthetic Limb Connectors?

Frigate’s connectors include isolated axial routing channels lined with medical-grade polymer sleeves for EMG and sensor wiring. Mechanical loads are decoupled from the cable path to prevent compression or shear damage. EMI shielding is achieved using grounded metal housings with dedicated isolation barriers. Signal performance remains stable during articulation, confirmed through TDR and EMI chamber testing. 

 

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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