Responses to 3D printing inquiry

Responses to 3D printing inquiry

Hunter Scott

11/18/2013

Original Post:

I'm looking for some information concerning 3D printing prosthetic
components and sockets. Has anybody heard of anyone using this new
technology in our field?

Responses:

I've been working with a buddy of mine from grad school trying to make this
happen or a couple months. We've managed to get a check socket and an afo
into mesh form (for the 3d modeling) but the biggest problem now isn't the
software or printer capabilities, it's the materials.

I'd love to hear what other people say.
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PDI/Dayton Artificial Limb has been using it.
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I believe that Northwestern school has a 3D printer and that they use it
for sockets.
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Check out the cover article in this month o&p business news
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My boss just asked me to look into this too. This was sparked by the
following article:
<URL Redacted>
prosthetic-controlled-bluetooth-headband-1387677
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I know that I've heard a story on NPR over the past year that involved 3D
printing and UE prosthetics, but I don't think it involved any
prosthetist/orthotists. I think it involved an engineer or 3D expert and an
end user who wasn't able to find what he wanted elsewhere. I'll try to
track down that story if you're interested.
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Northwestern university made some sockets on 3d printers back in the late
80's and went on to develope squirt shape
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  I have heard about 3D printing of components and it was addressed at our
national convention this year. There are some people in different parts of
Canada that have the equipment to do this.
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Talk with Alan Finnieston at Biosculptor. He has been researching it for
years and has talked with me about it a couple of times.
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We have been using this for a couple of years now on basically all of our
patients. Here is a video we recently posted.

<URL Redacted>
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I have heard that the New Jersey Institute of Technology is experimenting
with this and I saw an article about using it for fingers. I think it's
very useful for children. I will find you some links.
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Bespoke Innovations in San francisco area did some prosthetic covers
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There was an article a few months back in JPO. I think it was Hugh Herr
that had written an article about doing a socket that way. Also, OWW seems
to heading up some research on it. Please don't list my name as a
responder. Just wanted to give you a heads up if you hadn't see it.
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Mr. Scott,
I am a project engineer at Willow Wood. Ryan asked that I get in contact
with you regarding some questions about using 3d printing of prosthetic
sockets and components.

We have experience in this area using our SLS facilities at WW. In fact,
we ran a fairly in depth evaluation of the technology about two years ago.
In the process we:

   1. Evaluated the mechanical strength of ~100 traditional sockets
   purchased from C Fabs and private practitioners. The results were
   published in JRRD. Check for publications by Gerschutz and Haynes.
   2. Evaluated the strength of the materials used to make traditional
   sockets. The results of this were also published in JRRD. Check for
   publications by Gerschutz and Haynes
   3. Evaluated the strength of the materials available to a range of 3D
   printing processes.
   4. Selected SLS and a group of nylon materials based on a comparison of
   the mechanical properties of the available 3D materials relative to the
   materials in traditional use.
   5. Created a CAD/CAM system where we could scan a limb, modify the scan
   as needed to create the digital file to send to the SLS printer.
   6. Printed sockets.
   7. Evaluated the mechanical properties of SLS sockets relative to
   sockets currently produced and delivered by the industry.
   8. Patient tested SLS sockets for months at a time.

The basic results were that it is possible and, if done in full production,
it can probably be done economically and with much more repeatable results
than currently offered by current practices. The resulting sockets were
slightly heavier. However, they were actually as strong as most of the
carbon sockets sold, much more predictable in quality and strength, they
were very durable, the fit resulting from the CAD/CAM process was generally
very good, and patients generally liked the SLS sockets as well as
traditional sockets. Some preferred them. There were challenges.

   1. The initial costs of an SLS machine capable of printing large sockets
   runs into many hundreds of thousands of dollars. As such, it takes
   significant production volume to justify the initial expense. Our current
   thought is that running this process at a C-Fab might make sense if the
   market was ready for the change.
   2. The process is somewhat slow. However, his can also be overcome by
   volume production.
   3. There is a lot of inertia in the O&P field.
   4. There is a lot of inertia in the O&P field.
   5. There is a lot of...

At this point, we are continuing work in this field. We have ideas about
how to address the few shortcomings that we did identify and we use our SLS
facility on a regular basis. The repeatability, durability, and
flexibility of the shapes that can be build are winning points for the
process. We are looking at ways to capitalize on these aspects of the
process.
Please feel free to call if you have any ideas, questions, or if you would
just like to talk about the concept or the papers mentioned above. We are
optimistic about the long term prospects for rapid production techiniques
and are always happy to discuss ideas or reality checks from outside of the
WW bubble. Many of our best ideas start with collaboration with our
customers.

Thank you for your interest,


Hunter Scott, CP LP
Atlanta Prosthetics and Orthotics
Work: (770) 267-3711
Fax: (770) 267-3522
<URL Redacted>