Methods of producing a custom fitted prosthetic socket device for a residual limb include covering the distal end thereof with a liner, positioning the covered end within a socket cup to maintain a spaced relationship between the exterior of the liner and the interior of the socket cup, introducing an expandable, hardenable filler material into the socket cup, expanding the material to fill the volume between the liner and the socket cup, hardening the material, and removing the socket cup, hardened filler material, and liner, from the residual limb. Some methods include a filler material that hardens into a flexible solid foam cushioning layer, which may optionally form a bond between the socket cup and the liner, embedding the liner in the cushioning layer. Some methods include selecting a socket cup from a plurality of sized socket cups, and/or providing the plurality of sized socket cups.
