Background: Accurate evaluation of pressure distribution at the socket–limb interface is essential for improving prosthetic fit and comfort in transfemoral amputees. This study aimed to develop a proof-of-concept framework that integrates machine learning–based segmentation with the finite element method (FEM) to explore the feasibility of an initial workflow for residual-limb analysis during socket application. Methods: MRI data from a transfemoral amputee were processed using a custom image segmentation algorithm to extract adipose tissue, femur, and ischium, achieving high F-measure scores. The segmented tissues were reconstructed into 3D models, refined through outlier removal and surface smoothing, and used for FEM simulations in LS-DYNA. Pressure values were extracted at nine sensor locations and compared with experimental measurements to provide a preliminary qualitative assessment of model behaviour. Results: The results showed consistent polarity between measured and simulated values across all points. Moderate correspondence was observed at eight low-pressure locations, whereas a substantial discrepancy occurred at the ischial tuberosity (IS), the primary load-bearing site. This discrepancy likely reflects the combined influence of geometric deviation in the reconstructed ischium and the non-physiological medial boundary condition required to prevent unrealistic tissue displacement. This limitation indicates that the current formulation does not support reliable quantitative interpretation at clinically critical locations. Conclusions: Overall, the proposed framework provides an initial demonstration of the methodological feasibility of combining automated anatomical modeling with FEM for exploratory pressure evaluation, indicating that such an integrated pipeline may serve as a useful foundation for future development. While extensive refinement and validation are required before any quantitative or clinically meaningful application is possible, this work represents an early step toward more advanced computational investigations of transfemoral socket–limb interaction.

Accurate evaluation of pressure distribution at the socket–limb interface is essential for improving prosthetic fit and comfort in transfemoral amputees. This study aimed to develop a data-driven framework that integrates machine learning–based segmentation with finite element method (FEM) to quantitatively assess interface pressure during socket application. MRI data from a transfemoral amputee were processed using a custom image segmentation algorithm to extract adipose tissue, femur, and ischium, achieving high F-measure scores. The segmented tissues were reconstructed into 3D models, refined through outlier removal and surface smoothing, and used for FEM simulations in LS-DYNA. Pressure values were extracted at nine sensor locations and compared with experimental measurements. The results showed consistent polarity between measured and simulated values across all points. Furthermore, at the eight locations excluding the ischial tuberosity (IS) region, a statistically significant and moderately strong positive correlation was observed between measured and simulated pressures (r = 0.7485, p < 0.05). Notably, positive pressure regions demonstrated close agreement between experimental and simulated values, whereas the discrepancy observed at the IS region was likely influenced by the medial boundary conditions introduced to prevent unrealistic tissue displacement. This difference highlights a limitation of the current simulation setup. Overall, the proposed framework demonstrated reliable pressure estimation and offers a promising approach for personalized prosthetic socket design through automated anatomical modeling and simulation.

Background/Objectives: Statistical shape modeling (SSM) is used to describe transtibial residual-limb morphology for prosthetic socket design, simulation, and future structural testing. However, conventional intrinsic metrics such as compactness, generality, and specificity may not directly reflect geometric fidelity to the original shape. This study examined the relationship between geometric fidelity and SSM evaluation and assessed a cross-sectional shape representation framework for transtibial residual limbs. Methods: Residual-limb surfaces were acquired from 62 adults with unilateral transtibial amputation using a structured-light 3D scanner while preserving habitual limb posture. Two surface-based registration methods, non-rigid iterative closest point and Bayesian coherent point drift, were compared with a cross-sectional representation in which proximal and distal regions were sectioned separately and reconstructed by strip triangulation. Geometric fidelity to the original mesh was quantified using average symmetric surface distance (ASSD). SSM performance was evaluated using compactness, generality, and specificity. Results: The optimal cross-sectional configuration was 60 sections × 72 points. The proposed method showed the best geometric fidelity (ASSD, 1.30 ± 0.14 mm), followed by Bayesian coherent point drift (1.33 ± 0.14 mm) and non-rigid iterative closest point (1.48 ± 0.48 mm). Compactness was highest for the proposed method, reaching 95% cumulative variance in four modes, compared with five and seven modes, respectively, for the two surface-based methods. In geometry-space evaluation, the proposed method showed the lowest specificity error, while differences in generality were statistically significant but small in magnitude. Conclusions: Intrinsic SSM metrics alone were insufficient to judge registration quality in transtibial residual-limb modeling. The cross-sectional representation preserved the original surface geometry more faithfully than the evaluated surface-based methods while maintaining competitive SSM performance.