At Chinaplas 2025, BASF will present the Pro-Flex Terra foot prosthesis, co-created with the leading global prosthetic provider, Össur. Cellasto’s cutting-edge material solution, characterized by progressive stiffness and high impact strength, combines softness and flexibility with extraordinary energy return, allowing the Pro-Flex Terra foot prosthesis to embody an intuitive response behavior and replicate closely the human muscle-tendon motion.
The three-step Cellasto foam design addresses the limitations of traditional two-step designs. It adapts to a wide range of load conditions without mechanical or electrical adjustment, making it suitable for activities like slow walking, hiking, and high-impact sports in both extremely cold and hot environments. Additionally, it is ideal for use at the beach, pool, or in the shower. Users noted that they were rediscovering aspects of their mobility while using it.
Rigorous tests, including a full lifecycle assessment with over two million overloaded steps, confirmed the robustness and performance of Cellasto, which maintained its quality as well as on day one, even after extensive testing. The different foam densities for the serial product were fine-tuned during user tests to work in harmony with 9 specific user weight and categories. Cellasto application development engineers supported customer innovations from conception to production, which was implemented with an efficient tooling concept on fully automated mold lines.
“Our ambition was to combine the features of many prosthetic feet into one product. Össur designed the innovative Pro-Flex Terra to blend the softness and flexibility of a comfortable daily-use foot with the high energy return of an active foot, thereby merging two separate attributes in one design. Our partnership with Cellasto exemplifies a successful collaboration that has advanced prosthetic technology. By prioritizing comfort, performance, and durability, we strive to help our customers live through every step,” remarked Felix Starker, Product Designer at Össur.
“Cellasto offers a unique balance between comfort and functionality. We take great pride in partnering with Össur to enhance mobility and quality of life for prosthetic foot users worldwide. At Cellasto, we continue to explore tailored solutions for applications across all industries,” said Bjoern Kophstahl, Vice President, Global Business Management for Cellasto.
