Three-dimensional printing is widely used in many fields, including engineering, architecture and even medical purposes. The focus of the study is to obtain the ideal weight-to-performance ratio for making a 3D-printed part. The end products of the 3D-printed part are hugely affected by not only the material but also the printing parameters. The printing parameters to be highlighted for this study are the infill density, wall perimeter and layer height, which are the commonly adjusted parameters in 3D printing. The study will be divided into two parts, the simulation analysis and the experimental analysis, to confirm both results toward the trend of Young’s modulus for the material. It will then be analyzed and discussed toward any differences between the two results. The results showed that increasing the value of all three parameters will increase the tensile elasticity of the part.

Phocomelia is a congenital limb defect affecting the upper or lower limbs of newborns, significantly impacting their daily lives. Adaptive devices, such as prosthetic limbs, are crucial for helping individuals with phocomelia, yet designing and customizing these devices presents a complex challenge, as traditional prosthetic devices often do not cater to the specific needs of each patient due to their generic design. This study employs topology optimization and finite element analysis (FEA) to enhance the design and mechanical performance of these adaptive devices. The study focuses on improving design through material selection and topology optimization, analyzing mechanical behavior using FEA, and identifying potential improvements in strength and durability. Three materials—acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), and polyethylene terephthalate glycol (PETG)—are evaluated with weight reductions ranging from 10% to 50%. Computational software is used for modeling and analysis based on an existing model from Universiti Teknologi MARA (UiTM), incorporating applied forces and fixed points. Results indicate the stiffness-to-weight ratio for each material and mass reduction scenario, alongside stress, strain, and displacement analyses. This study aims to advance adaptive device design by enhancing functionality and affordability, ultimately improving the quality of life for phocomelia patients.