Customized Prosthetic Sleeves for Niche Environments

Publication ID: 24-11857439_0004_PTD
Published: October 28, 2025
Category:Specialized Variations & Niche Solutions

Legal Citation

pr1or.art Inc., “Customized Prosthetic Sleeves for Niche Environments,” Published Technical Disclosure No. 24-11857439_0004_PTD, Published October 28, 2025, available at https://archive.pr1or.art/24-11857439_0004_PTD
This technical disclosure describes improvements that would be readily apparent to a Person Having Ordinary Skill In The Art (PHOSITA) when considered in combination with the foundational architecture disclosed in U.S. Patent No. 11,857,439.

Summary of the Inventive Concept

A system and method for manufacturing customized prosthetic sleeves adapted to specific operational environments, including disaster relief, high-security facilities, extreme weather conditions, remote areas, and areas with limited access to medical resources.

Background and Problem Solved

The original patent disclosed a method for manufacturing customized sleeves for prosthetics, but it did not address the unique challenges of specific operational environments. The present inventive concept solves this problem by providing specialized variations and niche solutions for these environments, ensuring that individuals in need of prosthetics can receive customized sleeves regardless of their circumstances.

Detailed Description of the Inventive Concept

The inventive concept comprises a system and method for manufacturing customized prosthetic sleeves adapted to specific operational environments. For disaster relief environments, the system includes a portable mold of an end of a limb, a preform made of a heat-resistant elastomer material, and an injection device for injecting a polymer cross-linkable at high temperatures around the preform. For high-security facilities, the method involves providing a mold of an end of a limb, a preform made of a biocompatible elastomer material, and injecting a polymer with enhanced antimicrobial properties around the preform. For extreme weather conditions, the customized sleeve is designed with a preform made of a cold-resistant elastomer material and a polymer layer cross-linkable at low temperatures, ensuring a stable fit in temperatures below -20°C. For remote areas, the system includes a 3D printing device for creating a mold of an end of a limb, a preform made of a durable elastomer material, and an injection device for injecting a polymer with enhanced durability around the preform. For areas with limited access to medical resources, the method involves providing a mold of an end of a limb, a preform made of a low-cost elastomer material, and injecting a polymer with basic antimicrobial properties around the preform.

Novelty and Inventive Step

The inventive concept is novel in its adaptation of the original patent's method to specific operational environments, providing unique solutions for disaster relief, high-security facilities, extreme weather conditions, remote areas, and areas with limited access to medical resources. The inventive step lies in the combination of specialized materials, devices, and methods tailored to each environment, ensuring that customized prosthetic sleeves can be manufactured and used effectively in these contexts.

Alternative Embodiments and Variations

Alternative embodiments of the inventive concept could include using different types of elastomer materials, varying the design of the mold and preform, or incorporating additional features such as sensors or temperature control systems. Variations of the system and method could be implemented for other niche environments, such as search and rescue operations or space exploration.

Potential Commercial Applications and Market

The inventive concept has significant commercial potential in the prosthetics industry, particularly in the areas of disaster relief, high-security facilities, extreme weather conditions, remote areas, and areas with limited access to medical resources. The target market includes organizations and individuals involved in these environments, such as non-governmental organizations, government agencies, and medical professionals.

CPC Classifications

SectionClassGroup
A A61 A61F2/5046
B B29 B29C45/0053
B B29 B29C45/14065
B B29 B29C45/14336
B B29 B29C65/48
B B29 B29C66/729
A A61 A61F2002/5053
A A61 A61F2002/5056
A A61 A61F2002/7837
B B29 B29C2045/0079
B B29 B29C2045/14155
B B29 B29K2083/00
B B29 B29K2105/0061
B B29 B29L2031/7532

Field of Art

Medical Prosthetics Manufacturing, with expertise in elastomer-based sleeve fabrication, molding techniques, and polymer injection processes for customized prosthetic interfaces

Person of Ordinary Skill (PHOSITA) Profile

A biomedical engineer or materials scientist with advanced training in polymer engineering, prosthetic design, and manufacturing techniques, familiar with elastomer materials, injection molding, and medical device customization

Obviousness Rationale

A person having ordinary skill would recognize that the source patent's fundamental method of creating a customized prosthetic sleeve can be readily adapted to different environmental conditions by selecting appropriate materials and modifying injection parameters. The core manufacturing process remains substantially unchanged, with variations representing predictable design choices based on known material science principles. The PTD's environmental adaptations represent logical extensions of the original patent's core methodology.

Obvious Combinations & Variations

Source Patent Element
Silicone gel preform with variable thickness used in prosthetic sleeve manufacturing
PTD Variation
Specialized elastomer materials for specific environments (heat-resistant, cold-resistant, biocompatible)
Obviousness Reasoning
Material selection for specific performance characteristics is a routine design optimization that would be obvious to a skilled practitioner, involving known material science techniques of polymer modification
Source Patent Element
Manufacturing method involving molding and polymer injection at 20-25°C
PTD Variation
Injection processes adapted for low temperatures (below -20°C) or high-temperature environments
Obviousness Reasoning
Adjusting manufacturing parameters for temperature variations represents a predictable engineering solution within the known capabilities of polymer processing techniques
Source Patent Element
Basic prosthetic sleeve manufacturing method using elastomer preform
PTD Variation
Specialized manufacturing systems for remote areas using 3D printing and portable injection devices
Obviousness Reasoning
Integrating emerging manufacturing technologies like 3D printing represents an obvious technological progression for creating customized medical devices in resource-limited settings
Source Patent Element
Silicone-based sleeve manufacturing with injection of bi-component silicone
PTD Variation
Polymers with enhanced antimicrobial or durability properties for specific operational environments
Obviousness Reasoning
Incorporating functional additives into polymer matrices is a well-established technique for modifying material properties, representing a predictable engineering solution
35 U.S.C. § 103 Summary: Based on US Patent 11857439's disclosure of a customized prosthetic sleeve manufacturing method, the present publication demonstrates that variations in material selection, environmental adaptation, and manufacturing techniques represent obvious extensions of the prior art, rendering subsequent claims of novelty invalid under standard obviousness analysis. The disclosed variations constitute routine design optimizations that would be apparent to a person having ordinary skill in prosthetic manufacturing and materials engineering.

Original Patent Information

Patent NumberUS 11,857,439
TitleMethod for manufacturing a customized sleeve for a prosthesis