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Additive manufacturing enables new possibilities for the design of end products. These are rooted in the potentials of the manufacturing technology, such as flexible, tool-free production. These potentials can be used for the economic and flexible production of customized products. To support the use of the potentials, a development method was created which identifies optimization areas within a product. Therefore, the complexity is reduced by using of product functions. Characteristic functions and structural configurations are used to identify optimization areas. This contribution describes the application of the new development method to an existing mechanical transtibial prosthesis. In doing so optimization areas are identified which may make use of the potentials provided by additive manufacturing. One area is the interface between the prosthesis and the ground. By analyzing walking environments and the gait cycle the need for walking assistance on deformable surfaces was identified. Significant improvements were achieved through a functional integrated, additive manufactured foot sleeve.

Additive manufacturing (AM) technologies enable the design of new products due to their potentials. The potential of function integration can be extended through a combination of AM with a component integrating technology forming a hybrid integrating additive manufacturing technology (hiAM). With a created development method optimization areas within a product are identified on a functional level using characteristics, structural configurations and integrated functional areas. These are derived analysing examples in literature. The method is applied to a mechanical arm and hand prosthesis.

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