Prosthetic Chicken Leg

This is a custom 3D printed prosthetic leg for a chicken named Una. As of my writing this, the project is ongoing, so please check my blog post for additional files in case I fail to update this posting.

The models here include a scale model of Una's nub based on a 3D scan, two halves of a mold which can be used to make a silicone piece, five differently sized pieces which can be inserted into the mold box to ensure the silicone piece is custom fit to Una's nub, and then the main leg and clamping pieces (which you'd need three of). The leg and clamping pieces are designed to grab onto the silicone piece. The convex shape is supposed to keep the silicone from moving up and down relative to the 3D printed pieces, and the grooves are to keep the silicone from rotating relative to the plastic piece. It's designed for M3x20mm screws and nuts to be used to tighten the clamps around the silicone evenly to hopefully give a snug fit to the leg without hurting the chicken. 

There are no special printing instructions, but just use common sense. Orient the mold halves with the open part facing up to get a good seal when pouring silicone. I think it's best to lay the leg down on its side by about 60 or 75 degrees to get a good mix of strength in all parts of the geometry (like to keep layer lines parallel-ish to the force). I used 0.2mm layers, but any resolution should be fine. 

This is a custom model, so I don't expect it to be super helpful for anyone, but maybe it can give you some inspiration. If you're able to improve upon this, please let me know. You can find more detailed steps and my contact info on my website.