Abstract: A variety of prosthetic ankles have been successfully developed to reproduce the locomotor ability for lower limb amputees in daily lives. However, they have not been shown to sufficiently improve the natural gait mechanics commonly observed in comparison to the able-bodied, perhaps due to over-simplified designs of functional musculoskeletal structures in prostheses. In this study, a flexible bionic ankle prosthesis with joints covered by soft material inclusions is developed on the basis of the human musculoskeletal system. First, the healthy side ankle–foot bones of a below-knee amputee were reconstructed by CT imaging. Three types of polyurethane rubber material configurations were then designed to mimic the soft tissues around the human ankle, providing stability and flexibility. Finite element simulations were conducted to determine the proper design of the rubber materials, evaluate the ankle stiffness under different external conditions, and calculate the rotation axes of the ankle during walking. The results showed that the bionic ankle had variable stiffness properties and could adapt to various road surfaces. It also had rotation axes similar to that of the human ankle, thus restoring the function of the talocrural and subtalar joints. The inclination and deviation angles of the talocrural axis, 86.2° and 75.1°, respectively, as well as the angles of the subtalar axis, 40.1° and 29.9°, were consistent with the literature. Finally, dynamic characteristics were investigated by gait measurements on the same subject, and the flexible bionic ankle prosthesis demonstrated natural gait mechanics during walking in terms of ankle angles and moments.

Key words: Ankle prosthesis , · Bionic design , · Soft materials , · Variable stiffness , · Gait mechanics