1 Vol.:(0123456789) Scientific Reports | (2024) 14:6842 | https://doi.org/10.1038/s41598-024-57454-8 www.nature.com/scientificreports Investigation on three‑dimensional printed prosthetics leg sockets coated with different reinforcement materials: analysis on mechanical strength and microstructural Muhammad Hanif Ramlee 1,2* , Muhammad Imam Ammarullah 3,4,5,6* , Nurelisya Suraya Mohd Sukri 1 , Nur Syafiqah Faidzul Hassan 1 , Muhammad Hanif Baharuddin 1 & Mohammed Rafiq Abdul Kadir 7 Previous research has primarily focused on pre‑processing parameters such as design, material selection, and printing techniques to improve the strength of 3D‑printed prosthetic leg sockets. However, these methods fail to address the major challenges that arise post‑printing, namely failures at the distal end of the socket and susceptibility to shear failure. Addressing this gap, the study aims to enhance the mechanical properties of 3D‑printed prosthetic leg sockets through post‑processing techniques. Fifteen PLA + prosthetic leg sockets are fabricated and reinforced with four materials: carbon fiber, carbon‑Kevlar fiber, fiberglass, and cement. Mechanical and microstructural properties of the sockets are evaluated through axial compression testing and scanning electron microscopy (SEM). Results highlight superior attributes of cement‑reinforced sockets, exhibiting significantly higher yield strength (up to 89.57% more than counterparts) and higher Young’s modulus (up to 76.15% greater). SEM reveals correlations between microstructural properties and socket strength. These findings deepen the comprehension of 3D‑printed prosthetic leg socket post‑processing, presenting optimization prospects. Future research can focus on refining fabrication techniques, exploring alternative reinforcement materials, and investigating the long‑term durability and functionality of post‑processed 3D‑printed prosthetic leg sockets. Keywords 3D printing, Prosthetics leg, Post-processing, Reinforcement materials, Artificial leg A prosthetic leg socket is a structural link between an amputee’s residual limb and the prosthesis. Currently, where the complexity of the conventional method to manufacture prosthetic leg sockets is still a significant hurdle, there are promising prospects for integrating additive manufacturing (AM) as a fabrication process 1 . AM is a digital manufacturing technology that enables the creation of three-dimensional (3D) printed models or functional objects with sophisticated geometries 2–5 . To fabricate a 3D-printed prosthetic leg socket, a 3D scanner generates a positive mold of the residual limb, creating a 3D model that can be altered in computer-aided design (CAD) OPEN 1 Bone Biomechanics Laboratory (BBL), Department of Biomedical Engineering and Health Sciences, Faculty of Electrical Engineering, Universiti Teknologi Malaysia, Johor Bahru 81310, Johor, Malaysia. 2 Bioinspired Devices and Tissue Engineering (BIOINSPIRA) Research Group, Universiti Teknologi Malaysia, Johor Bahru 81310, Johor, Malaysia. 3 Department of Mechanical Engineering, Faculty of Engineering, Universitas Diponegoro, Semarang 50275, Central Java, Indonesia. 4 Undip Biomechanics Engineering and Research Centre (UBM-ERC), Universitas Diponegoro, Semarang 50275, Central Java, Indonesia. 5 Department of Mechanical Engineering, Faculty of Engineering, Universitas Pasundan, Bandung 40153, West Java, Indonesia. 6 Biomechanics and Biomedics Engineering Research Centre, Universitas Pasundan, Bandung 40153, West Java, Indonesia. 7 Department of Biomedical Engineering, Faculty of Engineering, Universiti Malaya, 50603 Kuala Lumpur, Federal Territory of Kuala Lumpur, Malaysia. * email: muhammad.hanif.ramlee@biomedical.utm.my; imamammarullah@gmail.com