Finite Element Analysis and Optimization of Transcarpal Prosthetic Arm for Pursuit Racing in Malaysian Para-Cycling

The main objective of this research is to design and optimize a transcarpal prosthetic arm tailored for Malaysian Para cyclists participating in pursuit racing. Current prosthetics often lacks in the strength-to-weight ratio and ergonomic efficiency for high-intensity cycling which affects athlete’s performance. Through collaboration with Malaysian para-cyclist, this project aims to develop a lightweight, durable transcarpal prosthetic arm through the application of Finite Element Analysis (FEA) and optimization techniques. The methodology utilizes computer-aided design (CAD) model using CATIA V5, based on the athlete’s residual limb, followed by materials selection and ANSYS for the FEA to evaluate stress distribution, fatigue resistance and deformation under race conditions. Material selections were done through multiple evaluation with unidirectional (UD) prepreg carbon fibre chosen for its strength and fatigue resistance. The simulation replicates race conditions including a 490.87N axial force that simulates pedalling and weight transfer, as well as a 1000N bolt pretension for screw connections. Among three design iteration, Design 3 features a superior overall performance by having the lowest deformation at 1.5005mm, low peak stress at 201.63 MPa and greater strain response at 0.0062755. This result validates the effectiveness of design optimization and improved biomechanical efficiency without altering weight. This research provides a framework to connect gaps in sports prosthetics and adaptive equipment, empowering para-athletes to compete in higher levels. Further validation through real-world testing is recommended to confirm the performance under dynamic race conditions.