Freedom in Every Step: Cellasto Helps Össur Deliver Softer, More Responsive Prosthetic Feet
Reading Time: 3 minutes
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Summary:
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Össur Pro-Flex Terra prosthetic foot boosts mobility with Cellasto
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BASF’s Cellasto foam enhances energy return and comfort
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Adaptive prosthetic tech needs no electronics or tuning
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Proven durable: 2M+ high-stress steps in lab testing
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Össur prosthetic innovation suits sport, daily use, and harsh terrain
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For prosthetic foot users, effective energy return is essential, as it replicates the way a healthy ankle stores and releases energy with each step. This process helps enhance walking comfort, balance, and reduces fatigue, allowing for smoother, more efficient movement. The Pro-Flex Terra, a collaborative creation by BASF, a renowned multinational chemical company, and Össur, a leading provider of orthopedic products, is designed with this in mind.
Unveiled at CHINAPLAS 2025, the Pro-Flex Terra features BASF’s Cellasto microcellular foam, renowned for its ability to manage impact forces and deliver high energy return through progressive stiffness. This technology helps the prosthetic foot respond naturally, closely imitating the behavior of real muscle-tendon structures.
Thanks to Cellasto’s three-step foam design, the Pro-Flex Terra adapts to various levels of stress and movement, eliminating the need for any mechanical or electronic adjustments. It is suitable for a wide range of activities, from slow walks to high-intensity sports and hiking.
Additionally, it maintains consistent performance in harsh conditions, such as extreme heat, cold, and wet environments like beaches, pools, or showers. Users have reported a renewed sense of mobility with this advanced prosthesis.
Users have reported a renewed sense of mobility with this advanced prosthesis.
Thorough testing—including a full lifecycle assessment with over two million overloaded steps—demonstrated the durability and consistent performance of Cellasto. Its quality remained high from day one, even after extensive testing.
Additionally, engineers modified the foam densities during user trials to suit nine specific user and size categories for the serial product line. Throughout development, BASF’s Cellasto application engineers supported Össur from the initial concept to production, which was achieved with an efficient tooling plan on fully automated mold lines.
According to Össur Product Designer Felix Starker, the company aimed to merge the features of different prosthetic feet into one product. With the Pro-Flex Terra, Össur achieved this by combining the comfort and flexibility of a daily-use foot with the energy performance of a more active model. Starker attributed this success to the company’s collaborative partnership with Cellasto, which helped Össur advance prosthetic technology by focusing on comfort, performance, and durability, ultimately improving the daily experience for customers.
Meanwhile, Bjoern Kophstahl, Cellasto’s vice president for global business management, said that Cellasto offers a perfect balance between comfort and functionality, making them a valued partner in enhancing mobility and quality of life for users of prosthetic feet worldwide. He added that the company remains dedicated to developing customized solutions for various industrial applications.
Related reading:
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