Lower-limb prosthetic technology has advanced remarkably over the past two decades, driven by innovations in materials engineering, computational design, and biomechanical analysis. Nevertheless, many commercially available prosthetic feet continue to rely on synthetic composite materials such as carbon fiber, which provide excellent mechanical performance but present significant environmental challenges due to their non-renewable and non-biodegradable nature. At the same time, the growing demand for affordable prosthetic devices—particularly in developing countries—has encouraged researchers to investigate alternative materials that combine structural reliability, sustainability, and cost-effectiveness.
The study reviewed here explores an innovative approach by developing a transtibial prosthetic foot using a ramie fiber-reinforced polylactic acid (PLA) composite. Rather than focusing solely on material characterization, the research integrates composite manufacturing, finite element simulation, prototype fabrication, and standardized mechanical validation into a comprehensive engineering workflow. This multidisciplinary investigation provides valuable insights for biomedical engineers, composite material researchers, mechanical designers, and healthcare innovators seeking environmentally responsible alternatives for future prosthetic development.
Bibliographic Information
| Item | Information |
|---|---|
| Article Title | Design, Simulation, and Static Testing of an Eco-Friendly Prosthetic Foot Using Ramie-PLA Composite |
| Authors | Iyan Sopiyan, Tresna P. Soemardi, Herry Purnomo, and Olivier Polit |
| Journal | Teknomekanik |
| Volume & Issue | Volume 8, Issue 1 |
| Publication Year | 2025 |
| Pages | 117–135 |
| DOI | https://doi.org/10.24036/teknomekanik.v8i1.36572 |
| Publisher | Universitas Negeri Padang |
| License | Creative Commons Attribution 4.0 International (CC BY 4.0) |
1. Research Background
- Biomedical engineering increasingly demands sustainable materials. Modern prosthetic devices must deliver excellent mechanical performance while simultaneously addressing environmental concerns associated with conventional engineering materials. The transition toward biodegradable and renewable composites has therefore become an important research direction in advanced healthcare engineering.
- Natural fiber-reinforced polymer composites have attracted significant attention. Previous studies have demonstrated that natural fibers can provide lightweight structures, favorable stiffness-to-weight ratios, corrosion resistance, and reduced environmental impacts compared with many traditional engineering materials. Among these materials, ramie fiber has emerged as a promising reinforcement because of its relatively high mechanical strength and abundant availability.
- Polylactic acid (PLA) offers an environmentally friendly polymer matrix. PLA is a biodegradable thermoplastic with attractive mechanical properties and has been widely investigated for biomedical and structural applications. When reinforced with natural fibers, PLA composites may provide an effective balance between mechanical performance and sustainability.
- Most commercial prosthetic feet still depend on carbon fiber composites. Carbon fiber provides exceptional stiffness and durability, making it the dominant material for high-performance prosthetic feet. However, its petroleum-based origin, non-biodegradable nature, and limited recyclability present environmental challenges that motivate the search for greener alternatives.
- Lower-limb amputation remains a major global healthcare challenge. Millions of individuals worldwide depend on prosthetic devices to restore mobility and independence. Many transtibial amputees require greater energy expenditure during walking than non-amputees, while access to advanced prosthetic technology remains limited by high manufacturing costs in many regions.
- Mechanical reliability is essential for prosthetic safety. Prosthetic feet are subjected to repeated loading during walking, making structural strength, fatigue resistance, and impact performance critical design considerations. Any alternative material must therefore be validated through engineering simulation and standardized mechanical testing before being considered for practical applications.
- Finite Element Method (FEM) has become an indispensable design tool. Computational simulation enables engineers to predict stress distribution, identify critical loading regions, and optimize prosthetic geometries before prototype fabrication. Integrating numerical analysis with experimental validation reduces development time while improving design reliability.
- The literature reveals a gap in sustainable prosthetic development. Although numerous studies have investigated natural fiber composites, relatively few have combined biodegradable ramie-PLA composites with complete prosthetic foot design, finite element analysis, prototype fabrication, and standardized structural validation under internationally recognized testing protocols.
- This research addresses both engineering performance and environmental sustainability. Instead of evaluating composite materials in isolation, the authors develop an integrated engineering workflow that encompasses material preparation, mechanical characterization, computational modeling, prototype manufacturing, and static testing. This comprehensive approach provides stronger evidence for the feasibility of bio-based composites in future prosthetic applications.
2. Research Objectives
- To design and develop a sustainable transtibial prosthetic foot prototype using ramie fiber-reinforced polylactic acid (PLA) composite as the primary structural material.
- To manufacture quasi-isotropic ramie-PLA composite laminates using a prepreg hot-press fabrication process suitable for prosthetic applications.
- To experimentally determine the tensile, flexural, and elastic properties of the developed composite according to relevant ASTM testing standards.
- To evaluate the structural performance of the prosthetic foot through Finite Element Method (FEM) simulations performed in ANSYS Workbench under representative gait loading conditions.
- To investigate stress distribution during the heel-strike and toe-off phases of human walking while ensuring that operational stresses remain within acceptable material limits.
- To fabricate a functional prosthetic foot prototype and validate its structural behavior through static mechanical testing based on ISO 22675 requirements.
- To compare numerical simulation results with experimental measurements obtained from strain-gauge-based static testing in order to assess the accuracy of the computational model.
- To demonstrate the technical feasibility of environmentally friendly ramie-PLA composites as a potential alternative material for next-generation lower-limb prosthetic systems.
3. Why This Research Matters
- Supports sustainable biomedical engineering. The study demonstrates how renewable natural fibers and biodegradable polymers can be integrated into medical device development without neglecting engineering performance requirements.
- Promotes environmentally responsible composite design. Replacing conventional carbon fiber with bio-based composite materials could reduce the environmental footprint associated with prosthetic manufacturing while encouraging wider adoption of sustainable engineering practices.
- Advances prosthetic engineering research. By combining material science, computational mechanics, composite manufacturing, and structural testing within a single study, the research provides a comprehensive engineering framework that may guide future prosthetic development projects.
- Improves accessibility to prosthetic technology. Natural fiber composites have the potential to reduce production costs by utilizing renewable and locally available resources, creating opportunities for more affordable prosthetic devices in developing countries.
- Strengthens digital engineering approaches. The integration of finite element simulation with standardized experimental validation illustrates how digital engineering tools can accelerate product development while minimizing costly design iterations.
- Contributes to sustainable manufacturing. The research aligns with broader efforts to replace petroleum-based engineering materials with renewable alternatives that support circular economy principles and environmentally responsible manufacturing.
- Creates interdisciplinary research opportunities. The findings are relevant not only to biomedical engineering but also to composite materials research, mechanical design, manufacturing engineering, biomechanics, and sustainable product development.
- Supports long-term healthcare innovation. Developing reliable eco-friendly prosthetic components contributes to future healthcare systems that prioritize both patient well-being and environmental sustainability, demonstrating that engineering innovation can address societal and ecological challenges simultaneously.
4. Research Methodology
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Research Type
This study employed an experimental engineering research approach integrated with computational simulation and prototype validation. Rather than evaluating material properties alone, the researchers developed a complete engineering workflow that combined material fabrication, numerical analysis, prototype manufacturing, and standardized mechanical testing to assess the feasibility of an eco-friendly transtibial prosthetic foot.
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Composite Material Development
The prosthetic foot was manufactured using a biodegradable ramie fiber-reinforced polylactic acid (PLA) composite. Ramie fibers served as the primary reinforcement, while PLA functioned as the polymer matrix. To improve interfacial bonding between the fibers and the matrix, the fabrication process incorporated isophorone diisocyanate (IPDI), tin (II) octoate, and triphenyl phosphite as compatibilizing agents before laminate production.
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Composite Manufacturing Process
Composite prepregs were produced by impregnating woven ramie fibers with dissolved PLA resin. After controlled storage under low-temperature conditions, the prepregs were consolidated using a hot-press manufacturing process. The laminate was fabricated under controlled temperature and pressure to obtain consistent composite quality before being cut into specimens for mechanical characterization and prototype production.
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Mechanical Characterization
Mechanical properties of the developed composite were experimentally evaluated using internationally recognized ASTM standards. Tensile testing, flexural testing, and EVA material testing were performed to determine the elastic modulus, tensile strength, flexural strength, and other engineering properties required for subsequent structural analysis. Statistical analysis was also conducted to evaluate the consistency of the experimental results.
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Finite Element Analysis (FEA)
The experimentally obtained material properties were incorporated into ANSYS Workbench for structural simulation. The prosthetic foot geometry was analyzed under representative gait loading conditions corresponding to the heel-strike and toe-off phases of walking. Composite failure behavior was evaluated using Tsai-Wu and Norris-McKinnon failure criteria to ensure that predicted stresses remained below allowable limits.
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Biomechanical Loading Conditions
Simulation conditions were developed based on standardized prosthetic loading protocols. The analysis assumed a user body mass of approximately 65 kg and walking conditions that generated loading equivalent to approximately 120% of body weight during heel strike and 110% during toe-off. These loading scenarios closely represent realistic operational conditions encountered during daily walking.
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Laminate Design Strategy
The prosthetic structure adopted a quasi-isotropic laminate configuration using a stacking sequence of 0°, 90°, and ±45°. This arrangement was selected to improve multidirectional mechanical performance while maintaining balanced structural behavior under complex loading conditions. Laminate thickness was determined through analytical calculations and subsequently verified using finite element simulation.
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Prototype Fabrication
Following numerical optimization, a full-scale prosthetic foot prototype was manufactured using the hot-press process. Separate upper and lower composite sections were produced before final assembly using mechanical fasteners and structural adhesive connections. The completed prototype closely matched the simulated design used during computational analysis.
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Experimental Validation
The fabricated prototype underwent static mechanical testing following ISO 22675 procedures. Strain gauges were installed at several critical locations to monitor stress during loading. Experimental measurements obtained during heel-strike and toe-off tests were compared with finite element predictions to evaluate the reliability of the numerical model.
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Engineering Evaluation
The overall engineering performance of the prosthetic foot was assessed by comparing experimental mechanical properties, finite element stress predictions, and prototype testing results. This integrated validation strategy enabled the researchers to determine whether the developed ramie-PLA composite satisfied the structural requirements necessary for safe prosthetic foot applications.
5. Key Findings
Ramie-PLA Composite Demonstrated Promising Mechanical Performance
The experimental characterization confirmed that the developed ramie-PLA composite possesses mechanical properties suitable for structural biomedical applications. Tensile and flexural testing showed that the laminate provides sufficient stiffness and strength to withstand the loading conditions expected during normal prosthetic foot operation. The measured elastic modulus and ultimate strength establish a solid mechanical foundation for utilizing biodegradable composites in lower-limb prosthetic structures.
Although the composite does not attempt to outperform advanced carbon fiber systems, the results demonstrate that environmentally friendly natural fiber composites can achieve structural performance appropriate for engineering design when properly manufactured and optimized. This finding strengthens the growing body of research supporting sustainable composite materials for medical devices.
Finite Element Simulation Successfully Predicted Structural Behavior
The finite element analysis accurately identified stress concentrations during both heel-strike and toe-off phases of the gait cycle. Numerical results indicated that normal and shear stresses remained below the allowable fatigue limits established for the composite laminate, suggesting that the proposed design possesses an adequate structural safety margin under the investigated loading conditions.
Equally important, the simulation enabled optimization of the prosthetic geometry before manufacturing. This demonstrates the effectiveness of integrating digital engineering tools into prosthetic development, allowing engineers to evaluate structural performance, reduce unnecessary prototype iterations, and improve overall design efficiency.
Static Testing Confirmed the Reliability of the Numerical Model
Experimental validation using strain gauges showed good agreement between measured stresses and finite element predictions. During standardized static loading, the prototype successfully withstood the prescribed heel-strike and toe-off loading conditions without exceeding allowable stress limits or exhibiting structural failure.
The close correspondence between simulation and experimental measurements increases confidence in the computational methodology employed in this study. It also demonstrates that finite element analysis can serve as a reliable engineering tool for future prosthetic optimization using natural fiber composite materials.
Quasi-Isotropic Laminate Configuration Improved Structural Stability
The selected quasi-isotropic stacking sequence distributed mechanical loads effectively throughout the prosthetic structure. Instead of concentrating stresses along a single fiber orientation, the multidirectional laminate configuration enabled more balanced stress transfer during complex loading experienced throughout the walking cycle.
This design strategy contributes to improved structural reliability and enhances resistance against localized failure mechanisms that commonly occur in laminated composite structures subjected to repeated biomechanical loading.
The Study Demonstrated the Feasibility of Sustainable Prosthetic Engineering
One of the most significant contributions of the research is the successful integration of sustainable materials into a complete prosthetic engineering workflow. The study illustrates that biodegradable natural fiber composites can progress beyond laboratory-scale material testing and be incorporated into realistic engineering design, manufacturing, simulation, and validation processes.
This achievement broadens the potential application of renewable composite materials within biomedical engineering while supporting ongoing efforts to reduce dependence on petroleum-based composite systems in healthcare technologies.
Composite Failure Analysis Identified Opportunities for Material Improvement
Microscopic examination of fractured specimens revealed that failure primarily occurred through fiber-matrix debonding and localized delamination. These observations indicate that the interface between ramie fibers and the PLA matrix remains one of the most influential factors governing composite performance.
Rather than representing a weakness of the overall concept, these findings provide valuable guidance for future material optimization. Improvements in fiber surface treatment, compatibilizer selection, or manufacturing processes may further enhance interfacial bonding and lead to even greater mechanical performance in future generations of sustainable prosthetic composites.
6. Scientific Contribution
- Introduces a sustainable material alternative for prosthetic engineering. The study demonstrates that ramie fiber-reinforced PLA composites can be engineered into a functional transtibial prosthetic foot, extending the application of biodegradable composites from material research to biomedical product development.
- Bridges materials science and prosthetic design. Rather than investigating composite properties independently, the research integrates material development, computational simulation, structural design, manufacturing, and mechanical validation into a unified engineering framework.
- Provides an experimentally validated computational design methodology. The finite element model was verified through standardized static testing, demonstrating that numerical simulation can accurately predict the structural response of natural fiber composite prosthetic components.
- Expands the application of natural fiber composites in healthcare engineering. While ramie-PLA composites have previously been investigated in material science, this work extends their application to structural biomedical devices that experience complex biomechanical loading conditions.
- Demonstrates the feasibility of quasi-isotropic laminate architecture. The selected laminate configuration effectively distributed multidirectional stresses encountered during walking, providing an engineering strategy for future composite prosthetic structures.
- Contributes to sustainable engineering research. By replacing petroleum-based reinforcement with renewable natural fibers, the study supports ongoing research toward environmentally responsible engineering materials for medical applications.
- Provides a reproducible engineering workflow. The combination of material preparation, ASTM characterization, finite element simulation, prototype fabrication, and ISO validation establishes a systematic methodology that can be adapted for future biomedical composite developments.
7. Industrial Implications
- Encourages sustainable prosthetic manufacturing. The successful use of ramie-PLA composites demonstrates that biodegradable materials can become viable alternatives for selected prosthetic components, reducing dependence on conventional synthetic composites.
- Supports cost-effective prosthetic production. Natural fibers such as ramie are renewable and relatively abundant, creating opportunities to develop more affordable prosthetic devices without sacrificing essential structural performance.
- Accelerates digital engineering implementation. The integration of finite element simulation with experimental validation illustrates how virtual prototyping can shorten product development cycles while reducing manufacturing costs and physical prototype iterations.
- Strengthens composite manufacturing practices. The hot-press prepreg process demonstrated in this study provides a practical manufacturing route for producing high-quality natural fiber composite laminates suitable for structural engineering applications.
- Improves engineering design decision-making. The validated computational model enables engineers to optimize laminate thickness, fiber orientation, and structural geometry before fabrication, improving product reliability while minimizing development risks.
- Supports sustainable healthcare technology. The findings encourage manufacturers to explore renewable materials for future medical devices, aligning healthcare innovation with broader sustainability objectives.
- Provides opportunities for localized manufacturing. Countries with abundant natural fiber resources may benefit from domestic production of bio-based prosthetic components, reducing dependence on imported high-cost composite materials.
- Demonstrates broader engineering applicability. Although developed for prosthetic feet, the design methodology may also be adapted for lightweight composite products used in orthotics, rehabilitation devices, sporting equipment, and other biomechanical engineering applications.
8. Research Limitations
- The investigation primarily focused on static structural performance. Dynamic fatigue testing under long-term cyclic loading was beyond the scope of the present study and remains an important step before clinical implementation.
- The finite element simulations were developed using a representative user body mass and walking condition. Additional studies involving broader anthropometric variations would improve the generalizability of the design.
- Only one composite material configuration and laminate architecture were investigated. Alternative stacking sequences, fiber volume fractions, and reinforcement strategies may further improve structural performance.
- Prototype validation was limited to laboratory-based mechanical testing. Clinical evaluations involving prosthetic users were not included and would provide valuable information regarding comfort, gait performance, durability, and user acceptance.
- Microscopic observations identified fiber-matrix debonding and delamination as dominant failure mechanisms. Additional studies focusing on interfacial modification could further enhance composite performance.
- Environmental durability under prolonged exposure to moisture, temperature fluctuations, ultraviolet radiation, and biological environments was not comprehensively investigated.
- The study concentrated on structural feasibility rather than large-scale manufacturing. Industrial production challenges, process optimization, and economic analysis remain opportunities for future investigation.
9. Future Research Opportunities
- Investigate the long-term fatigue performance of ramie-PLA prosthetic feet under millions of gait cycles to evaluate durability throughout extended service life.
- Conduct clinical trials involving transtibial amputees to assess walking comfort, gait biomechanics, energy expenditure, and overall user satisfaction under real-world conditions.
- Optimize fiber surface treatments and compatibilizer formulations to improve fiber-matrix adhesion and reduce interfacial debonding observed during fracture analysis.
- Evaluate alternative natural fiber reinforcements or hybrid composite systems that combine ramie fibers with other sustainable materials to further enhance mechanical performance.
- Investigate moisture absorption, biodegradation behavior, thermal stability, and environmental aging to determine long-term durability under various operating environments.
- Develop topology optimization and generative design approaches integrated with finite element analysis to reduce structural weight while maintaining mechanical safety.
- Integrate additive manufacturing technologies with bio-based composite materials to enable customized prosthetic designs tailored to individual patients.
- Perform comprehensive life cycle assessment (LCA) and carbon footprint analyses to quantify the environmental benefits of biodegradable prosthetic materials compared with conventional carbon fiber systems.
- Investigate the economic feasibility of large-scale manufacturing, including production cost analysis, supply chain considerations, and industrial scalability.
- Explore the application of the proposed composite design methodology to other biomedical devices, including orthoses, rehabilitation equipment, exoskeleton components, and lightweight assistive technologies.
10. Potential for Public Policy Citation (Overton)
Although this study is primarily an engineering and biomedical materials investigation, its findings demonstrate meaningful potential to inform future public policy discussions related to sustainable healthcare technologies, environmentally responsible manufacturing, and biomedical innovation. Rather than proposing policy recommendations directly, the research provides scientific evidence supporting the development of renewable composite materials for assistive medical devices.
The integration of biodegradable natural fiber composites into prosthetic engineering aligns with several international sustainability initiatives, particularly those promoting circular economy practices, green manufacturing, and sustainable industrial innovation. As governments increasingly encourage environmentally responsible production, studies such as this may serve as supporting technical references for future innovation strategies and research roadmaps.
- Healthcare Innovation Policies. The study provides scientific evidence supporting research investment in sustainable biomedical technologies and affordable prosthetic device development.
- Sustainable Manufacturing Roadmaps. The demonstrated use of renewable natural fiber composites may contribute to national strategies promoting environmentally friendly manufacturing and bio-based materials.
- Research and Innovation Funding. Government agencies supporting advanced materials, biomedical engineering, and green technology research may consider this work when identifying priority research areas.
- Bioeconomy Development. Countries producing natural fibers such as ramie may use similar research to strengthen bio-based industrial ecosystems and increase the value of agricultural resources.
- Engineering Education. Universities and professional organizations may cite this work when developing curricula that integrate sustainable materials, digital engineering, and biomedical product design.
- Technical Guidelines. Although the article does not establish new engineering standards, its validated methodology may support future discussions concerning design practices for bio-based prosthetic components.
Overall, the article possesses moderate potential for policy citation. Its greatest value lies in providing scientific and engineering evidence that may inform future government reports, sustainable manufacturing initiatives, biomedical innovation programs, and long-term research strategies rather than serving as a direct basis for regulatory standards.
11. Who Should Read This Paper?
- Biomedical engineering researchers.
- Mechanical engineers working in product design and structural analysis.
- Composite material scientists.
- Researchers specializing in sustainable materials and green manufacturing.
- Graduate students in mechanical, biomedical, and materials engineering.
- Finite Element Analysis (FEA) specialists.
- Prosthetic and orthotic device designers.
- Medical device manufacturers.
- Healthcare technology innovators.
- Industrial practitioners involved in composite manufacturing.
- Researchers working on biodegradable polymer composites.
- Government agencies supporting sustainable healthcare innovation.
- Engineering educators developing courses on composite materials and biomedical design.
12. Final Thoughts
This research presents a comprehensive engineering investigation into the development of an environmentally friendly transtibial prosthetic foot using ramie fiber-reinforced PLA composite. One of its major strengths lies in the integration of multiple engineering disciplines, including composite material development, finite element analysis, structural design, prototype manufacturing, and standardized mechanical validation. Rather than evaluating material properties alone, the study demonstrates a complete engineering workflow that strengthens confidence in the practical feasibility of sustainable composite materials for biomedical applications.
Another notable contribution is the successful combination of computational simulation with experimental verification. The agreement between numerical predictions and laboratory testing illustrates the effectiveness of digital engineering approaches in reducing development uncertainty while supporting reliable structural design. Although further investigations involving fatigue performance, environmental durability, and clinical evaluation remain necessary, the reported findings establish a solid scientific foundation for future research.
Overall, the article represents a valuable contribution to sustainable biomedical engineering by demonstrating that renewable natural fiber composites can be incorporated into functional prosthetic systems without compromising essential structural requirements. Its multidisciplinary methodology, practical relevance, and emphasis on environmentally responsible engineering make it a meaningful reference for researchers seeking innovative approaches to future healthcare technologies.
Suggested Citation
UNP–Teknomekanik Style
Sopiyan, I., Soemardi, T. P., Purnomo, H., & Polit, O. (2025). Design, simulation, and static testing of an eco-friendly prosthetic foot using ramie-PLA composite. Teknomekanik, 8(1), 117–135. https://doi.org/10.24036/teknomekanik.v8i1.36572
APA (7th Edition)
Sopiyan, I., Soemardi, T. P., Purnomo, H., & Polit, O. (2025). Design, simulation, and static testing of an eco-friendly prosthetic foot using ramie-PLA composite. Teknomekanik, 8(1), 117–135. https://doi.org/10.24036/teknomekanik.v8i1.36572
IEEE Style
I. Sopiyan, T. P. Soemardi, H. Purnomo, and O. Polit, "Design, simulation, and static testing of an eco-friendly prosthetic foot using ramie-PLA composite," Teknomekanik, vol. 8, no. 1, pp. 117–135, 2025. doi: 10.24036/teknomekanik.v8i1.36572.
Harvard Style
Sopiyan, I., Soemardi, T.P., Purnomo, H. and Polit, O., 2025. Design, simulation, and static testing of an eco-friendly prosthetic foot using ramie-PLA composite. Teknomekanik, 8(1), pp.117–135. Available at: https://doi.org/10.24036/teknomekanik.v8i1.36572.
Vancouver Style
Sopiyan I, Soemardi TP, Purnomo H, Polit O. Design, simulation, and static testing of an eco-friendly prosthetic foot using ramie-PLA composite. Teknomekanik. 2025;8(1):117–135. Available from: https://doi.org/10.24036/teknomekanik.v8i1.36572.
Chicago (Author–Date)
Sopiyan, Iyan, Tresna P. Soemardi, Herry Purnomo, and Olivier Polit. 2025. "Design, Simulation, and Static Testing of an Eco-Friendly Prosthetic Foot Using Ramie-PLA Composite." Teknomekanik 8 (1): 117–135. https://doi.org/10.24036/teknomekanik.v8i1.36572.
MLA (9th Edition)
Sopiyan, Iyan, et al. "Design, Simulation, and Static Testing of an Eco-Friendly Prosthetic Foot Using Ramie-PLA Composite." Teknomekanik, vol. 8, no. 1, 2025, pp. 117–135. https://doi.org/10.24036/teknomekanik.v8i1.36572.
Editorial Note: This blog post is an independent scholarly review intended for educational and scientific communication purposes. It summarizes and discusses the published article in the author's own words while providing full attribution to the original publication, consistent with the principles of the CC BY 4.0 license.

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