Industrial - Bachelor

Airliner Prosthetic Socket System

Airliner is a prosthetic socket system built around accessibility. Combining a ventilated, FDM-printed PBT shell with a flexible variable-density MJF lattice liner, it features a built-in air pump for adjustable fit. Printable anywhere, Airliner puts comfortable sockets within reach of more people.

Jordan Greensill

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AIRLINER SOCKET SYSTEM

The new benchmark for prosthetic socket comfort

ACCESSIBILITY

Prosthetic sockets are expensive, have long lead times, and are tied to a clinic, requiring specialised equipment and hours of manual labour by trained professionals and prosthetists to manufacture a single unit. Airliner is built to change that. The design lives as a digital file that can be 3D printed anywhere, so a cracked shell or worn liner can be replaced anywhere in the world without a prosthetist appointment. The rigid shell prints on a standard FDM printer in durable PBT, and the liner in TPU/TPA on an MJF printer. The system can be up to 10x cheaper than standard socket solutions. For many people, especially those who must self-fund their prosthesis, this manufacturing format and reduced price point can be the difference between getting a comfortable socket or going without. The W.H.O. estimates that 9 in 10 people who need assistive products cannot access them, and Airliner is designed to make a comfortable, custom prosthetic socket accessible to people who would previously have had no access at all.

BREATHABILITY

Heat and moisture are among the most persistent problems in prosthetic socket design. A standard socket seals the residual limb in a warm, enclosed environment for hours at a time, with no path for sweat or heat to escape. The consequences are well documented: thermal discomfort, volume fluctuation, and skin conditions including contact dermatitis, ingrown hairs, blisters, and fungal infection. This was reflected in the research behind Airliner. Only 1 of 22 lower-limb prosthetic users surveyed reported no skin conditions, and consulted prosthetists confirmed that almost every client they see experiences some form of skin problem linked to their socket. Despite this, existing liner and socket design largely fail to address the issue. Airliner treats breathability as a core design requirement.

CELL LINER

At the interface of the residual limb and the prosthetic, the Airliner Cell Liner replaces the traditional solid foam or silicone liner with a flexible TPU volumetric lattice. The open cell structure and ventilation pores allow air and moisture to pass through the material instead of being trapped against the skin. Cell density is parametrically varied across the liner based on proximity to heavy loading zones. This results in a liner that is softer and more open where comfort and airflow matter most, but firmer where the limb requires support.

ANATOMICA SOCKET

The Airliner Anatomica Socket continues this approach to ventilation. A perforated wall promotes airflow and allows heat to escape the socket rather than accumulate behind a rigid barrier. The perforations are sized to ventilate effectively while remaining comfortable and maintaining a clean and futuristic aesthetic. The liner and shell create a continuous path for airflow from the skin to the outside environment.

ADJUSTABILITY

A residual limb does not stay the same size. Limb volume shifts through the day with activity, heat and fluid, and a socket that fits in the morning can be loose or painful by the afternoon. Airliner lets the wearer correct this on the spot. An inbuilt bulb pump – the first of its kind in this application – inflates an air bladder between the shell and the liner, gently compressing the lattice and tightening the fit. A pressure release valve eases it off again, and a locking dial secures the setting, preventing accidental adjustment and stopping water entering the system, so the socket is just as reliable in the ocean or the pool as on land.

RIGHT TO REPAIR

Many prosthetic sockets are sealed, one-piece components, and a single component failing can mean replacing the whole socket and waiting on a clinic. Airliner is designed to be maintained and repaired by anyone. The system is modular, with a separate shell, cap, locking dial and liner, so a worn or damaged part can be replaced on its own. The liner can be washed by machine or rinsed with a hose, which makes daily hygiene simple. The air system uses standard components that can be easily sourced, and the shell can be reshaped with a heat gun when adjustments are needed. Because every printed part exists as a digital file, a replacement is a print away.

PROTOTYPING

Name
Airliner Socket System Research Report
File Type
application
File Size
1 B
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Name
Technical Package
File Type
application
File Size
1 B
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Jordan Greensill

Jordan has a passion for human-centred design, product development and rapid prototyping. Having long held an interest in prosthetics and their design, he saw his Capstone project as the ideal opportunity to explore innovative ways to improve the comfort and adaptability of prosthetic limb interfaces.

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