Enhancing the versatility of dynamic prosthetic feet in the context of the nova foot by Gyromotics

Despite a global need for prosthetic care, only 5–10% lower-limb amputees currently have access, emphasizing the urgent demand for affordable, high-performance solutions. In response to this need, Gyromotics introduced Nova, a modular, cost-effective prosthetic foot. While it offers adaptability and ease of maintenance, it lacks an adjustable ankle joint, limiting comfort, terrain adaptability, and footwear compatibility. This thesis addresses that limitation by redesigning Gyromotics' ankle to improve performance, usability, and reduce weight. Two design concepts were developed and evaluated using FEM analysis. The results were measured against project-specific design criteria and the ISO standard 22675. The final concept—a manually adjustable ankle joint—achieves a sagittal range of motion of 145° in dorsiflexion and 76° in plantarflexion, enhancing adaptability, comfort, and therefore, performance. Usability testing revealed increased usability compared to Gyromotics' previous ankle joint model, although further testing is necessary to confirm performance under dynamic loading conditions. The design process revealed key mechanical and ergonomic factors that formed a modular design framework for broader integration across Gyromotics' and other prosthetic companies' product portfolios. This work contributes to the development of accessible, regulation-compliant prosthetic solutions that improve the quality of life and reduce the social and economic burden on amputees worldwide.