The large numbers of terrorist attacks and wars in Iraq led to increase the numbers of amputees. However, typically a large number of the amputations are trans-femoral or above knee (AK). In this work, manufacturing a socket by using new method (REVO FIT SOLUTION) for manufacturing trans-femoral prosthetic socket by two molding. The main objectives of this work is to design and manufacturing of above knee prosthetic socket by revo fit solution method to increase suspension, decrease weight of socket and easier to doffing and donning especially for the elderly. The experimental work included subjecting the socket materials to tensile and fatigue testing. The results show that the mechanical properties for (4 layers of carbon fiber) are (sic)(ult) = 213MPa, (sic)(y) = 135MPa and E = 3.5GPa. The Fatigue life equation for carbon fiber are (sic) = 739.6 (N-f)(-0.13) and The fatigue limit are 90 MPa The data of gait cycle (force plate) and Interface pressure between the socket and the residual limb was calculated using F-Socket device, the pressure in anterior region equal to (222Kpa)between the socket and the residual limb for patient(male) suffering from above knee right leg amputation and age(42)year. The finite element technique (ANSYS) is used to analyze the model of prosthetic socket and calculate the safety factor, equivalent (Von Mises) stress, and total deformation. The obtained results from ANSYS gave the profile of safety factor of fatigue, for AK with carbon fiber is (1.26).
