In this episode, we talk about a system developed by MIT researchers to optimize new material development and LifeNabled - a non-profit organization - that leverages 3D printing technology and generative design to develop cost-effective, bespoke prosthetics. As always, you can find these and other interesting &amp; impactful engineering articles on Wevolver.com.<iframe height="200px" width="100%" frameborder="no" scrolling="no" seamless="" src="https://player.simplecast.com/1c1300b7-8e1f-4179-8389-075cca962518?dark=false" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-gtm-yt-inspected-12="true"></iframe>&nbsp;<hr>This podcast is sponsored by <a href="https://www2.mouser.com/" id="isPasted" rel="nofollow" target="_blank">Mouser Electronics</a>. &nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM1ODQyMzM0MjkzLU1vdXNlci1zcG9uc29yLTEtYS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib"><hr><h3 id="isPasted">EPISODE NOTES</h3>(1:11) - &nbsp;Accelerating New Material Discovery 🔬⚗️(11:40) -&nbsp;<a href="https://www.wevolver.com/article/walking-on-the-worlds-most-advanced-prosthetics-in-the-jungles-of-guatemala" target="_blank">World’s Most Advanced Prosthetics 🦾🦿</a>Episode 42 was brought to you by Mouser Electronics, Farbod &amp; Daniel’s favorite electronics distributor. Click <a href="https://www.youtube.com/watch?v=Sjhl3UgbWxI" target="_blank">here&nbsp;</a>to learn more about Mouser's 3D printed car project hosted by Grant Imahara.<hr>About the podcast:Every day, some of the most innovative universities, companies, and individual technology developers share their knowledge on Wevolver. To ensure we can also provide this knowledge for the growing group of podcast listeners, we started a collaboration with two young engineers, Daniel Scott Mitchell &amp; Farbod Moghaddam who discuss the most interesting content in this podcast series.&nbsp;To learn more about this show, please visit the&nbsp;<a href="https://www.wevolver.com/profile/the.next.byte" target="_blank">shows page</a>. By following the page, you will get automatic updates by email when a new show is published.Be sure to give us a follow and review on&nbsp;<a href="https://podcasts.apple.com/nl/podcast/the-next-byte/id1548255861?l=en" rel="nofollow" target="_blank">Apple</a> podcasts,&nbsp;<a href="https://open.spotify.com/show/6lPPsRtegnivsRUEsQ09R7?si=IPMiah7xT_apJtPjqvXMlA" rel="nofollow" target="_blank">Spotify</a>, and most of your favorite podcast platforms!Take a few seconds to leave us a review. It really helps!&nbsp;<a href="https://apple.co/2RIsbZ2" rel="nofollow" target="_blank">https://apple.co/2RIsbZ2</a>if you do it and send us proof, we’ll give you a shoutout on the show.

In this episode, we talk about a system developed by MIT researchers to optimize new material development and LifeNabled - a non-profit organization - that leverages 3D printing technology and generative design to develop cost-effective, bespoke prosthetics. 

Podcast: World's Most Advanced Prosthetics

This article was discussed in our <a data-saferedirecturl="https://www.google.com/url?q=https://www.wevolver.com/profile/the.next.byte&source=gmail&ust=1640817319915000&usg=AOvVaw2nPRdRwJrXSYYeM9RCFu5x" href="https://www.wevolver.com/profile/the.next.byte" id="isPasted" rel="noopener noreferrer" target="_blank">Next Byte podcast</a>.&nbsp;<iframe height="200px" width="100%" frameborder="no" scrolling="no" seamless="" src="https://player.simplecast.com/1c1300b7-8e1f-4179-8389-075cca962518?dark=false" class="fr-draggable"></iframe>The full article will continue below.<hr><h2 id="isPasted">Background</h2>Brent Wright is a Certified Prosthetist and Orthotist. Together with his wife, Meredith Wright, they co-founded <a href="https://lifenabled.org/" target="_blank">LifeNabaled</a>, a non-profit provider of prosthetic solutions for the developing world, based in Raleigh, North Carolina, USA.Brent and his team are changing the lives of amputees in northern Guatemala who do not have the means to afford prosthetic care. Their bi-yearly clinics have treated hundreds of patients over the past 15 years.<div class="fr-img-space-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM0ODAxNzg5NTQyLUxpZmVOYWJsZWQtblRvcG9sb2d5LUNTLTFfSG9zcGl0YWwuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">Hospital Shalom is the only facility that provides prosthetics care to patients of the Petén region in northern Guatemala.&nbsp;</div>However, fabricating prostheses is a highly technical job. Evaluating, manufacturing, and fitting prostheses to the 30-50 patients during the week-long clinics took a physical toll on Brent and his team of volunteers.For their latest clinic, Brent and his team applied their years of experience in prostheses fabrication and additive manufacturing to develop a fully digital workflow. In this case study, we walk you through the steps they followed — from 3D scanning to design and manufacture — to create custom, 3D printed prosthetic sockets based on patient data in a cost-effective manner.<blockquote>“People who could not possibly afford a prosthesis now have the best device in the world. Without nTopology, none of this would be possible”<cite>Brent Wright, Co-Founder and Clinical Director at LifeNabled</cite></blockquote><h2>Traditional Vs. Digital Fabrication of Prostheses</h2>Traditional fabrication of prostheses is a laborious process. Since each socket needs to offer a custom-made fit for each patient, the fabrication is entirely manual. Typically, there are three steps involved in the process:<ul><li>First, the Prosthetist takes a cast of the amputee’s missing extremity during patient evaluation.</li><li>Then, they use the cast to create a custom mold to thermoform the socket. The socket is connected to off-the-shelf components to manufacture the prosthesis.</li><li>Finally, the Prosthetist fits the prosthetic device to the patient and makes the necessary adjustments to ensure a good fit.</li></ul><div class="fr-img-space-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM0ODAxODE3MzE0LUxpZmVOYWJsZWQtblRvcG9sb2d5LUNTLTJfUHJvY2Vzcy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">Manual fabrication of prostheses is a time-consuming, expertise-intensive, and laborious process.&nbsp;</div>Brent’s vision is to fully digitize the design and manufacturing steps. These steps are the most expertise-demanding phases of the prostheses fabrication process. At the same time, his team can train locals (or guide them through video calls) to perform the evaluation and fitting steps, eliminating the need for an expert to be present in the remote location.As a proof of concept, the team cut the cord to traditional manufacturing in the last clinic and followed a fully digital process. By digitizing the entire workflow, they can focus on making the process scalable and as cost-effective as possible.Here’s an overview of the new digital workflow:<ul><li>First, two team members flew to Guatemala to take 3D scans. In just two days, they were able to evaluate 35 amputees.</li><li>Then, over the next two weeks, Brent designed and customized each device and manufactured the sockets using HP’s MJF 3D printing technology.</li><li>Finally, the team returned to Guatemala a month later to deliver the devices and fit them to the patients.</li></ul><div class="fr-img-space-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM0ODAxODQyODc3LUxpZmVOYWJsZWQtblRvcG9sb2d5LUNTLTNfRGlnaXRhbC1GYWJyaWNhdGlvbi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">Digital fabrication of prostheses is streamlined. First, a 3D scan of the patient is taken (left) and then the custom socket and inner lining can be 3D printed from a digital design (right).&nbsp;</div>The results were astounding! All patients left the clinic walking on the most advanced prosthesis in the world. Moreover, the team achieved this result with a fraction of the effort. “We worked hard during that time, but we worked smart, and we were able to easily take the scans we needed so that when we came back, we were more efficient and valuable,” Brent Wright mentioned.<h2>Flexible 3D Printed Inner Liners</h2>The inner liner is an essential part of the prosthesis. The socket must be comfortable to the wearer while working or during prolonged hours of use. Moreover, it has to be breathable to ensure good hygiene. “We need to make sure that the prosthesis breathes, especially in the jungles of Guatemala,” mentioned Brent.However, traditional gel-like inner liners are not very breathable, cost more than $160, and have a limited life span of only 3 to 6 months in the tropical climates of Guatemala. This cost is prohibitively expensive for the local people who live on $2 to $3 a day.Brent’s team wanted to replace the expensive liners with knitted socks. Socks are very affordable, breathable, easily customizable, and washable. To ensure comfort, the team turned to 3D printed foams to design a flexible inner socket liner.<div class="fr-img-space-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM0ODAxODY1MzY4LUxpZmVOYWJsZWQtblRvcG9sb2d5LUNTLTRfblRvcC1PdmVydmlldy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">The final design of one of the 30+ custom-made flexible inner linings — designed in nTopology&nbsp;</div>3D printed foams are flexible <a href="https://ntopology.com/lattice-structures/" target="_blank">lattice structures</a> that imitate the properties of traditional foams. They are manufactured from an elastic material like TPU and offer additional benefits over conventional foams.For example, their properties can be tuned (from soft foam to stiff plastic) according to the physiology or preferences of the patient. This effect can be achieved by closely controlling the design input parameters of the lattice, such as beam thickness and porosity, using advanced <a href="https://ntopology.com/ntopology-software/" target="_blank">engineering design software</a> like nTopology.<h2>From 3D Scan to Manufacturing</h2>Even after the team has determined the 3D printed foam design parameters to achieve the desired cushioning, applying it to 30+ custom socket designs would be a challenge. Without nTopology, this step would be a “brutal process” according to Brent. The legacy software he was using prior to nTopology would often crush or take hours to generate a result.<blockquote>“Designing custom flexible inner liners was going to be a challenging task if we would do it in any other software other than nTopology. Once the workflow was done, all I had to do was to swap out meshes. The process ran over and over again.”<cite>Brent Wright, Co-Founder and Clinical Director at LifeNabled</cite></blockquote>The workflow is semi-automated and straightforward to implement. Here’s the overview:<ul><li>Using the mesh of the patient’s 3D scan data as input, they first generated a shell with variable thickness.</li><li>They then used nTopology’s latticing blocks to create a flexible inner liner that provided the necessary level of cushioning.</li><li>To repeat the process and generate a new design, they only had to swap in a new input mesh with 3D scan data from another patient.</li></ul>With nTopology’s reusable workflows, the team saved more than a whole day of error-prone computational processing during the design phase and produced higher-quality and error-free results.<div class="fr-img-space-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM0ODAxODkwNzE2LUxpZmVOYWJsZWQtblRvcG9sb2d5LUNTLTVfblRvcC1Qcm9jZXNzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 766px;" class="fr-fic fr-dib">Overview of the design process in nTopology — from importing a 3D scan mesh to exporting a manufacturing-ready 3MF mesh file&nbsp;</div>For manufacturing, the team opted for HP’s Multi Jet Fusion 3D printing process in TPU. This process and material combination is excellent for manufacturing flexible lattice structures with variable thickness for padding. TPU is also very durable, making it an ideal option for the jungle of Guatemala.Overall, this digital process saved the team 2-3 days of fabrication and replaced a laborious manual step with streamlined digital manufacturing.<h2>Changing Lives</h2>Beyond the technological achievements, this is a human story. There is little to no access to prosthetic care in these regions of Guatemala. Since the vast majority of these amputees live under a few dollars a day, affording a prosthesis is simply not an option.<div class="fr-img-space-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM0ODAxOTEzNzI3LUxpZmVOYWJsZWQtblRvcG9sb2d5LUNTLTZfUGF0aWVudHMuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">Three of the 30+ patients fitted with their new 3D printed prosthetic devices.&nbsp;</div>Because Brent’s team has been doing these clinics for so long, they have seen how a prosthesis can change a patient’s life.For example, 15 years ago, they started treating a young child when he was only three years old. Due to his condition, all four extremities were drastically affected by either amputation or congenital defects.Without the prostheses, he would be destined to a life of poverty and begging on the streets. Instead, the young man is now going to accounting school to become an accountant, and he will be able to provide for his family.<h2>The Next Steps</h2>Brent’s goal is to create a global network of prosthetic device providers for the developing world. With digital manufacturing and engineering design tools like nTopology, this dream is achievable.<blockquote>“There are millions of people that need prostheses worldwide. It’s a team effort to reach all of them. This is a human story. This is not a story of how we get a profit out of humans. It is a story of how we get people walking.”<cite>Brent Wright, Co-Founder and Clinical Director at LifeNabled</cite></blockquote>There are multiple industrial-grade 3D printing systems located worldwide (even in developing countries) that could be leveraged to manufacture the needed prosthetic devices. Local physicians can be trained through video calls to evaluate the patient and fit the prostheses. As for the design of the device, this can be generated using the automated processes that Brent’s team has developed.From a technical perspective, Brent continues to refine his designs to make them even more cost-effective. For example, his team is currently creating lighter socket ribs with a simulation-driven geometry using a <a href="https://ntopology.com/field-driven-design/" target="_blank">field-driven design</a> approach.<hr>This case study was first published on the <a href="https://ntopology.com/case-studies/3d-printed-prosthetics-guatemala/" id="isPasted" rel="noopener noreferrer" target="_blank">nTopology blog</a>.

LifeNabled volunteers and designers created a fully digital workflow to produce custom 3D printed prosthetic sockets with flexible inner liners. Now, 35 patients in the jungle of Guatemala are walking on the most advanced prosthetic and orthotic devices in the world.

Walking on the World's Most Advanced Prosthetics in the Jungles of Guatemala

Ben Choi was a runner-up in our <a href="https://www.wevolver.com/article/make-it-real-3d-printing-challenge" rel="noopener noreferrer" target="_blank">Make It Real 3D Printing Challenge</a>. His idea was to create a very low-cost brain-controlled prosthetic arm.After <a data-saferedirecturl="https://www.google.com/url?q=https://click.convertkit-mail2.com/75uqqk0evdi8h74rgzhz/8gh5rv68tohgx5x65dsk/aHR0cHM6Ly93d3cueW91dHViZS5jb20vd2F0Y2g_dj04UUVDb0xzQktrOA%3D%3D&source=gmail&ust=1619597341559000&usg=AFQjCNEzNhOPuVvr61dRvT_bm3Teht4Jrg" href="https://click.convertkit-mail2.com/75uqqk0evdi8h74rgzhz/8gh5rv68tohgx5x65dsk/aHR0cHM6Ly93d3cueW91dHViZS5jb20vd2F0Y2g_dj04UUVDb0xzQktrOA==" rel="noopener noreferrer" target="_blank">working with Ben to re-design his prosthetic arm for additive manufacturing using COR Alpha</a>, we were ecstatic to receive this update from him:Last month, I competed in the Fairfax County Regional Science and Engineering Fair, where I won the fair's&nbsp;Grand Prize&nbsp;and took home additional awards from the Air Force, IEEE, ASME, and several other sponsors. I was selected to advance to the Regeneron International Science and Engineering Fair (ISEF), the world's premier pre-college science fair, where I'll compete next month for over $4M in scholarship money and prizes alongside students from around the globe.We printed Ben's re-designed robot arm using <a data-saferedirecturl="https://www.google.com/url?q=https://click.convertkit-mail2.com/75uqqk0evdi8h74rgzhz/kkhmh6h839309vtl/aHR0cHM6Ly9wb2x5c3BlY3RyYS5jb20vYWxwaGEv&source=gmail&ust=1619597341559000&usg=AFQjCNE5ZTwztJFk5PmsFA-9SZaqpAC3LA" href="https://click.convertkit-mail2.com/75uqqk0evdi8h74rgzhz/kkhmh6h839309vtl/aHR0cHM6Ly9wb2x5c3BlY3RyYS5jb20vYWxwaGEv" rel="noopener noreferrer" target="_blank">COR Alpha</a> to give it the durability required for real-world applications.These durable, engineering-grade parts are suitable for the rigors of everyday use, and offer an innovative way to keep the cost of prosthetics low. We are wishing him luck at the Regeneron International Science and Engineering Fair next month.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1619527945206-unnamed.jpg" style="width: 545px;" class="fr-fic fr-dib"><h2>polySpectra makes it real for emerging designers</h2> Sponsored by polySpectra, The 2020 Make is Real Challenge was an incredible experience to witness some of the world’s most creative designers show off their ideas. During the competition, Ben Choi was awarded runner-up for his brain-powered prosthetic arm design.<a data-saferedirecturl="https://www.google.com/url?q=https://click.convertkit-mail2.com/75uqqk0evdi8h74rgzhz/qvh8h7h8060m69il/aHR0cHM6Ly93d3cud2V2b2x2ZXIuY29tL2FydGljbGUvbW90b3JiaWtlLWJyYWNrZXQtYmFzZWQtb24tYmlvbWltaWNyeS13aW5zLXRoZS1tYWtlLWl0LXJlYWwtM2QtcHJpbnRpbmctY2hhbGxlbmdl&source=gmail&ust=1619597341559000&usg=AFQjCNFAEEo87pvz_eLXLcdAEmMZFSUhdw" href="https://click.convertkit-mail2.com/75uqqk0evdi8h74rgzhz/qvh8h7h8060m69il/aHR0cHM6Ly93d3cud2V2b2x2ZXIuY29tL2FydGljbGUvbW90b3JiaWtlLWJyYWNrZXQtYmFzZWQtb24tYmlvbWltaWNyeS13aW5zLXRoZS1tYWtlLWl0LXJlYWwtM2QtcHJpbnRpbmctY2hhbGxlbmdl" rel="noopener noreferrer" target="_blank">Read more about last year’s winning designers</a><a data-saferedirecturl="https://www.google.com/url?q=https://click.convertkit-mail2.com/75uqqk0evdi8h74rgzhz/vqhxzwnzirhndkd9k0sg/aHR0cHM6Ly93d3cueW91dHViZS5jb20vd2F0Y2g_dj04UUVDb0xzQktrOA%3D%3D&source=gmail&ust=1619597341559000&usg=AFQjCNGrwb8NE-TLHd7PSQ0Xa_i5FIyC6A" href="https://click.convertkit-mail2.com/75uqqk0evdi8h74rgzhz/vqhxzwnzirhndkd9k0sg/aHR0cHM6Ly93d3cueW91dHViZS5jb20vd2F0Y2g_dj04UUVDb0xzQktrOA==" rel="noopener noreferrer" target="_blank">See how we used our DfAM workflow to help redesign Ben's arm for production additive manufacturing</a>

He was a runner-up in our Make It Real 3D Printing Challenge. His idea was to create a very low-cost brain-controlled prosthetic arm.

A 3D printed prosthetic arm controlled with your brain

"I think a hero is an ordinary individual who finds strength to persevere and endure in spite of overwhelming obstacles."These are Christopher Reeve's words. The iconic actor portrayed Superman in the 1978 blockbuster and its three later sequels. Reeve himself had to endure such obstacles towards the end of his life after becoming paralyzed from the shoulders down following a horse-riding accident.Today, as life imitates art, a combination of adversity and technology creates the next generation superheroes. Like Limbitless Solutions, a non-profit organization spun-off from the University of Central Florida. The team of now former students is developing technology that empowers children with limb differences.Amongst a range of accessibility solutions, the company creates personalized 3D printed prosthetic 'bionic' arms. Customized to resemble popular superhero bodysuits from movies and video games, the prosthetic dramatically improve the wearer's life quality.<h2>Advanced electronics</h2>To make the limb work, non-invasive electromyographic (EMG) sensors pick up signals generated by muscle movements in the child's arm. The sensors are stickers placed on the upper arm above muscle groups that move when flexed. When an EMG signal is detected, the bionic arm actuates. Below this is a socket to hold the prosthetic in place, matched to the individual child, and it fits regardless of whether or not the elbow is present. The forearm section of the bionic arm contains a battery pack that powers the motors controlling the multi-gesture movements.The hand unit contains the core electronics and motors for the fine control of the individual fingers. This unit includes an Insight SiP ISP1507-AX RF module based on Nordic Semiconductor's nRF52832 SoC. It enables the bionic limb to be set-up, adjusted, and monitored wirelessly via an iOS or Android partner app. For example, by configuring the app, you can determine the degree of muscle-flexing required to generate a particular force in the fingers. The app also provides easy access to status information such as the battery level.<h2>Practice makes perfect</h2>Learning to use a new arm takes practice; determining the various thresholds of muscle strength, for example, is difficult. So to make it fun and engaging, Limbitless Solutions has gamified the process. The Nordic-powered Insight SiP module acts as the Bluetooth LE wireless controller for a computer- or tablet-based game. The games take a classic level-based approach, starting with simple gestures such as opening and closing the hand and then unlocking additional, more complex manipulations as each level is completed.In addition to the looking part, the prosthetic arm must be comfortable, lightweight, and easy to use. The miniaturized eight by eight by 1 mm module is suitable for this purpose as it is for any other space-constrained application. Meanwhile, the Bluetooth LE connectivity allows parents to easily calibrate and adjust the arm from their smartphone, using a wireless technology they readily understand.<h2>Affordable technology</h2>Cosmetically realistic myoelectric hands that open and close can cost $20,000 to $30,000 or even more, while a neuroprosthetic arm may cost as much as $100,000. By combining cost-effective 3D printing with affordable electronics and wireless technology, the company believes it can reduce production cost to as little as $5000 per bionic arm. Essential if the technology is to become widespread as children outgrow prosthetics quickly.As a natural next step, the company has expanded its vision to support adults with limb differences—particularly veterans and first responders—of which there are unfortunately many in the United States. According to the Amputee Coalition, nearly two million people live with limb loss in the U.S. Approximately 185,000 amputations take place each year, a number expected to double by 2050.<h2>Project expansion</h2>Through the process of a clinical trial, Limbitless Solutions has so far gifted 40 bionic arms to 36 children and teenagers. By expanding its R&amp;D and manufacturing capabilities soon, the company hopes to increase to 100 through gifts and donations. If successful, the project could give families and children hope worldwide and create thousands of more superheroes in the process.<hr>This article was first published on Nordic's&nbsp;<a href="https://blog.nordicsemi.com/getconnected" rel="nofollow" target="_blank"></a><a href="https://blog.nordicsemi.com/getconnected?utm_campaign=2021%20wevolver" rel="nofollow" target="_blank">Get Connected Blog</a>.

By combining cost-effective 3D printing with affordable electronics and wireless technology, new accessibility solutions empower children with limb differences.

Smart limbs make heroes by design

With the increased accessibility and democratization of technologies that allow for rapid design iteration and customization, such as 3D printing, more and more innovative groups are taking the initiative to reevaluate how the use of this technology can improve upon existing systems. One of these groups is DiveDesign, who is working to use 3D printing to optimize the process of creating custom full limb pet prosthetics. In this article, we share their story: from the partnerships they&rsquo;ve created, through the research and development that went into their new process, to the lives they&rsquo;ve changed along the way.&nbsp;<h2 dir="ltr">Identifying An Opportunity&nbsp;</h2><a href="https://www.divedesignco.com/" target="_blank">DiveDesign</a> is the creation of Adam Hecht and Alex Tholl, who started their product development studio while still in college. While they mainly offer their services such as design research and strategy, concept development, prototyping, engineering, and brand development, their shared interest in technology has expanded their business and outlook towards finding opportunities for leveraging technology to improve upon existing systems used to design products.The team discovered one of these opportunities through their introduction to Derrick Campana of <a href="https://bionicpets.org/" target="_blank">Bionic Pets</a>, a leading provider of animal orthotics and prosthetics. Campana has been creating animal orthotic and prosthetic devices since 2005, and has provided custom braces and prosthetics for thousands of animals throughout his career. From speaking with Campana, Hecht and Tholl learned of the frustrations involved with the current process of creating full limb prosthetic devices for dogs, which had the ability to become a large portion of Bionic Pet&rsquo;s business.&nbsp;Traditionally, to create a full limb prosthetic (when the dog is missing an entire front leg), a negative mold is created of the patient using 3M ACE style bandages that is hardened using Plaster of Paris. Then, plastic sheets are heated and bent around the negative mold. Afterwards, it is trimmed and finished, and the foam and leg hardware components are attached.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1589852049169-unnamed+%286%29.png">Traditional method of creating the full limb prosthetics&nbsp; Although Campana has refined the process of creating full limb prosthetics, there were still many areas for improvement. While creating a brace takes little less than 2 hours, the process of creating a full limb prosthetic can usually take up to 15-20 (depending on the size of the prosthetic), and oftentimes does not account for adjustments after test fitting.Hecht and Tholl realized that there was an opportunity to improve upon this process. Leaning on their experience with 3D printing and scanning, they partnered with Campana to create a new method for creating full limb pet prosthetics.&nbsp;<h2 dir="ltr">Designing A New Process</h2>Hecht and Tholl began with the idea that by 3D scanning the negative mold and using the scan to create a 3D-printable customized prosthetic model, the need for heating, bending and finishing the plastic sheets would be eliminated, saving hours of manual labor.In addition to saved time, there were other advantages to this new approach: by incorporating digital tools into the process, it was now easier to modify the prosthetic after test fitting if needed. Through 3D printing the prosthetic, there would be more options for materiality, which would allow the prosthetic to be optimized for comfort, breathability, and flexibility.&nbsp;Another goal for the new process was to allow the workload to be distributed within a team, which was not an option with the existing process. &ldquo;For example,&rdquo; Tholl explained, &ldquo;(in the past) if Derrick was too busy one week, no body jackets got made because he&rsquo;s the only one who can make them. With the new process, we wanted to be able to train a team to support the process.&rdquo;&nbsp;With this in mind, the team began testing their new approach. They started by 3D scanning the Plaster of Paris molds and manipulating the scans with preexisting CAD tools. It was after preparing multiple prosthetic models for printing with these tools that they realized the extensive amount of manual digital labor that it required. &ldquo;We knew that creating a digital tool to perform the same actions with minimal user input was the key to a sustainable model.&rdquo; stated Hecht.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1589852032851-pasted+image+0+%281%29.png">3D scanning a negative mold&nbsp; <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1589852146357-pasted+image+0+%282%29.png">Development of the new algorithm&nbsp;This realization led them to partnering with Chris Landau of <a href="https://www.landau.design/" target="_blank">Landau Design + Technology&nbsp;</a>to create an algorithm specifically for generating prosthetic models from 3D scans to aid them in their process. Through this algorithm, it was possible to generate finalized 3D printable models of the prosthetics in a fraction of the time. It also allowed for further customization of each prosthetic through changing mount positions, thicknesses, and more.<h2 dir="ltr">Research &amp; Development</h2>With considerations towards cost, processing and printing time, and comfort, Hecht and Tholl designed and printed countless iterations of the prosthetics and worked with Landau to fine-tune the features of the algorithm. &ldquo;To be honest, the first design was us making sure we could even print something that could fit a large dog and be comfortable. Derrick at Bionic Pets sat with us for many hours going over the importances of support placement, sizing, flexibility, strength.&rdquo; Tholl recalled. &ldquo;Not only did we want the new design to be faster to make, we also wanted it to be a better product for the dog.&rdquo; Hecht added.The largest challenge throughout development came with finding a material to print the prosthetics with. &ldquo;We tried at least 10 different materials before landing on TPU,&rdquo; Tholl stated. TPU, or thermoplastic polyurethane, is a plastic known for its elasticity and high abrasion resistance. &ldquo;With this material we found the perfect combination of flex for comfort, and strength for support. It also enabled us to print a heavily ventilated pattern that enabled more breathability, unlike other materials that would have required being printed solid.&rdquo;&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1589852191030-pasted+image+0+%283%29.png">Prosthetic 3D printed with TPU &nbsp;Other characteristics of TPU that made it a good choice for printing the prosthetics were its microbial resistance, water resistance, and ability to be applied on or near the skin, which were important considerations when planning for the prolonged attachment to the patient.&nbsp;As with any thorough design development, it was important to validate that the product would function as intended for the end user, and meet all the necessary comfort and safety requirements. However, this user validation was unlike any DiveDesign had tackled in the past. &ldquo;It was tough because we had so many criteria to meet that would allow Derrick to approve our methods. Most importantly, we wanted to make sure that the fit was right. We were also looking to ensure that it moved with the dog and did not restrict them, was breathable and wouldn&rsquo;t cause discomfort, and it could withstand the expected wear and tear.&rdquo; explained Tholl.Fortunately, there were pet families who were willing to participate in the initial testing under Campana&rsquo;s supervision. This allowed DiveDesign to be confident that the prosthetics they were sending out to future patients were up to Campana&rsquo;s standards.&nbsp;One of these families were the owners of a dog named Hope, who volunteered to test one of the finalized prosthetics made through the new process. &ldquo;Hope&rsquo;s family really helped us to make sure what we were creating functioned in the way that it needed to, and Derrick was present digitally to watch and make sure his standards were being exceeded.&rdquo; Hecht explained.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1589852229109-pasted+image+0+%284%29.png">Test fitting Hope&rsquo;s full limb prostheticThrough families like Hope&rsquo;s, the team was able to conduct invaluable testing that allowed them to confirm that their process produced a viable alternative to traditional prosthetics, as well as better understand the unique challenges that came with every patient.<h2 dir="ltr">Creating The Prosthetics</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1589852304525-pasted+image+0+%285%29.png">Preparing prosthetics for shipment&nbsp;Once the process had been tested and verified,the recurring orders for full limb prosthetics that Bionic Pets was receiving could be fulfilled using the new 3D printing-centric process. To date, the team has completed over 30 orders for prosthetics, with more coming in every day. As they are fine-tuning the process, the partnership between DiveDesign, Campana, and Landau has remained crucial. The prosthetics are being closely monitored by Campana, and the algorithm is continuing to be developed under the guidance of Landau.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1589852731963-1241243123123.png">Fully assembled prosthetics &nbsp;While this endeavour has been a large undertaking for the team, the joy of seeing their prosthetics being used to change the lives of pets and their families has made it well worth it. &ldquo;Seeing (the pets&rsquo;) progress as they learn to move with the prosthetic..seeing them run for the first time, it&rsquo;s great to see.&rdquo; Hecht said. &ldquo;It&rsquo;s like an indescribable feeling. Never in a million years did we ever think we&rsquo;d be developing animal prosthetics using 3D printing.&rdquo; Tholl added.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1589852759499-12565474.png" style="width: 788px;" class="fr-fic fr-dib"><h2 dir="ltr">Looking To The Future</h2>As production of the prosthetics continues, the team is keeping their mind on expanding their operations. With the assistance of 3D printing service centers such as <a href="https://www.gcreate.com/" target="_blank">gCreate</a> in Brooklyn, NY, they are working to keep up with the large influx of orders they are receiving each month.&nbsp;For Hecht and Tholl, this project has inspired them to continue finding ways to use the technology they have available to them to solve problems and help others. &ldquo;We are excited to see where we will go from here, and what further applications for 3D printing we will find in the future.&rdquo; said Tholl.&nbsp;You can learn more about this project through<a href="https://www.divedesignco.com/work/bionic-pets" target="_blank">&nbsp;DiveDesign&rsquo;s</a> website, and by following <a href="https://www.instagram.com/divedesignco/?hl=en" target="_blank">DiveDesign</a> and <a href="https://www.instagram.com/bionicpets/?hl=en" target="_blank">Bionic Pets</a> on Instagram. You can also learn more about the story of two of their patients, Turbo Roo &amp; Thor, on Campana&rsquo;s new show <a href="https://www.byutv.org/player/8d089869-c4d2-40f2-a7b2-e718a216952e/wizard-of-paws-turbo-roo-thor" target="_blank">The Wizard of Paws</a> on BYUtv.&nbsp;<hr>References:<ul style="list-style-type: circle;"><li><a href="https://www.divedesignco.com/" target="_blank">https://www.divedesignco.com/</a></li><li><a href="https://bionicpets.org/" target="_blank">https://bionicpets.org/</a></li><li><a href="https://www.landau.design/" target="_blank">https://www.landau.design/</a></li><li><a href="https://www.byutv.org/player/8d089869-c4d2-40f2-a7b2-e718a216952e/wizard-of-paws-turbo-roo-thor" target="_blank">https://www.byutv.org/player/8d089869-c4d2-40f2-a7b2-e718a216952e/wizard-of-paws-turbo-roo-thor</a></li></ul>

A New Jersey-based product development studio has paired with an algorithm developer and one of the nation’s leading animal orthotists to optimize the process of creating full-limb pet prosthetics.

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