UNO Researchers Looking for Study Participants to Test 3D Printed Prosthetic Arms

It’s necessary to perform studies on medical devices, 3D printed or otherwise, to make sure they’re working the way they’re supposed to be. Some examples we’ve heard about include: a Virginia Tech researcher used sensors to compile data about how well 3D printed amniotic band prosthetics were performing, researchers from TU Delft evaluated the level of functionality for a 3D printed hand prosthetic, and a team from the University of Nebraska at Omaha (UNO) investigated how a 3D printed partial finger prosthesis changed the patient’s quality of life. Now, UNO researchers have received funding to study how the brain adapts to using 3D printed prosthetic limbs, and they’re looking for research volunteers.

Rue Gillespie has a cap fitted to her head at the labs in the Biomechanics Research Building on Tuesday, Dec. 17, 2019, in Omaha, Nebraska. The cap was used to help read her brain’s activity as she performs tasks with her right arm and her 3D printed prosthetic arm.

The team was given a Research Project Grant (R01) from the National Institutes of Health (NIH), which will fund its investigation into changes in neural activity of children who have been regularly using a 3D printed prosthetic arm. The researchers need 40 children, between the ages of 3 and 17, with upper limb differences caused by Amniotic Band Syndrome or other congenital differences, to participate in the study, and e-NABLE is helping them get the word out.

Jorge M. Zuniga, PhD, takes photographs of Rue Gillespie’s arms during a visit to the labs at the Biomechanics Research Building.

Jorge Zuniga, PhD, a UNO associate professor of biomechanics, said, “Essentially what we’ll do with this research study is to try and look at their brain and see how the brain of young children adapt to the use of our prosthesis.”

Zuniga, who designed the Cyborg Beast prosthetic hand for e-NABLE, and Brian Knarr, PhD, another biomechanics associate professor at UNO, are the co-principal investigators for this study, which is building on Zuniga’s prior research to design and produce more affordable 3D printable prosthetic arms for children.

Most typical prosthetic limbs generally cost between $4,000-$20,000, but a children’s prosthesis can be 3D printed and constructed for much less – as little as $50. This lower cost is very helpful, as kids can quickly outgrow, or damage, their prostheses. 3D printing can ensure easy replacement, which in turn helps the children who need them feel more normal.

Jorge M. Zuniga, PhD, measures Rue Gillespie’s arm as her mother Holly holds her during a visit to the labs at the Biomechanics Research Building.

Zuniga explained, “What we do here is basically provide child-friendly prosthetic devices to children that are born without a limb or lose a limb due to an accident.”

Rue Gillespie participates in tests at the labs in the Biomechanics Research Building. To the right is certified hand therapist Jean M. Peck, left. The researchers were looking at the activity in Rue’s brain as she uses her prosthetic arm, which was 3D printed at the lab.

If you know of a child who might be interested and is able to participate in this UNO study, or if you just want more information about the research, email Zuniga at: jmzuniga@unomaha.edu.

So, how do you know if a child qualifies for this important study? First, they have to be between 3 and 17 years of age, with congenital upper limb reductions of the hand (partial hand) or arm (trans-radial). They must not have any musculoskeletal injuries in the upper limbs or skin abrasions, and participants with normal upper limb function have to be able to complete the tests. Finally, they need to be able to travel to the university from any domestic destination.

Rue Gillespie wears a cap fitted to her head at the labs in the Biomechanics Research Building, which was used to help read her brain’s activity as she performs tasks with her right arm and her 3D printed prosthetic arm.

Children who are chosen to be study participants will need to visit the laboratory in the Biomechanics Research Building at the university, accompanied by a parent, on two different occasions eight weeks apart. Zuniga and the research team will provide participants with a 3D printed prosthesis to keep, and between the visits, the child will have to perform several games using the prosthesis. During the visits, they will be asked to wear it and take part in different games, like moving toys or blocks around, while also wearing a cap with attached sensors so their brain activity can be measured. Additionally, multiple measurements of the child’s arms will be taken.

Jorge M. Zuniga, PhD, helps Rue Gillespie put on her prosthesis before she is run through a series of tests on Wednesday, Jan. 15, 2020, in Omaha, Nebraska, at the Gillespie home.

Participants and their families will receive the 3D printed prosthesis at no cost, and will also be provided with a small stipend for participating. Their travel arrangements, transportation, and hotel accommodations – from any domestic destination – will also be covered.

What do you think about this study? Discuss this story and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

(Source: e-NABLE)

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3D Printing for the Segmental Scapula Prosthesis  

In the recently published ‘Application of a three-dimensional printed segmental scapula prosthesis in the treatment of scapula tumors,’ authors Linglong Deng, Xing Zhao, Chi Wei, Wengiang Qu, Li Yu, and Shaobo Zhu explore better ways to salvage limbs, focusing on the potential found in 3D printing.

While there are a host of benefits that make 3D printing enticing to the medical community overall—from the affordability factor to speed in production—what is most groundbreaking is the ability to offer patient-specific treatment. For this study, the authors focused on the effects of chondrosarcoma has on the scapula (a part of the body most commonly known as the shoulder blade).

Imaging examination findings of the left shoulder. (a) An X-ray showed an irregular shadow with a bone lesion on the scapula, situated in the S1 region. (b) A computed tomography scan revealed a moderate low-density bony lesion.

Due to aggressive tumors caused by chondrosarcoma, along with the resulting irregular patterns, limb salvage is usually recommended. Offering implants is known to be a challenge, and while limb salvage is often the best course of action, that does not mean it is simple. Today, chondrosarcomas are responsible for 20 percent of malignant bone tumors, stealing functionality from the shoulder for many patients, as well as shortening their lives in all too many cases.

“After resection of the tumor, we were eager to obtain a prosthesis with the same size and shape as the original removed portion without the tumor,” stated the researchers. “Hence, we viewed a mirror model of the scapula from the healthy side as an affected side implant. Consequently, having used mirror imaging technology, we synthesized the 3D image file of the S1 region of the left scapula without tumor and named it N-S1 (that is the prosthesis) according to the right scapula. Finally, the STL files were uploaded to a Tornier 3D printer (SAS, Montbonnot, France) to acquire a solid 3D model consisting of nylon resin material.”

Ultimately, the prosthesis was created from titanium and screwed into the scapula. After four weeks, the patient was able to move his hand, elbow, and shoulder, and is still in good condition with no pain in the shoulder. The researchers point out that 3D printing allows for ‘accurate reconstruction,’ but there is much to be considered before performing a successful procedure like this as the prosthesis must always be customized for the patient due the irregularity of tumors, leaving it properly shaped and stable for connection to what is left of the scapula after the mass is removed.

Major intraoperative surgical procedures. (a) The osteotomy navigation template was attached to the scapula landmark to assist with tumor resection. (b) The excised tumor tissue. (c) The remaining rotator cuff was reconstructed with the prosthesis.

With 3D printing, the researchers were able to simulate the procedure, training ahead of time, as well as contouring the reconstructive plate. The operation was successful, streamlined due to the previous simulation, and with a ‘perfect match’ shown between the prosthesis and scapula. They did note some constrictions, however:

  • The entire process—from 3D design to completion of surgery—was time-consuming.
  • The technology and materials were expensive.
  • Follow-up time was ‘relatively short.’

Overall though, with 3D printing they were successful in reconstruction, customization, and even more with the allowed simplification of operations which are generally otherwise complicated.

“The 3D printing technology can fulfill the requirements of a highly individualized design, thereby displaying unique advantages in the manufacturing of the implant,” concluded the researchers.

The impacts that 3D printing is having on the medical realm are enormous, and 3D printed models as well as implants have changed the lives of patients all over the world, educating surgeons and medical students about tumors and necessary surgeries, and offering new methods of treatment. What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.

Solid three-dimensional model of the left scapula and preoperative simulation. (a) A navigation template stuck to the removed portion of the scapula (S1). (b,d) The nylon and titanium alloy prostheses (N-S1) were printed using mirror imaging technique. Many holes were designed at the edge of the prosthesis for soft tissue reconstruction. (c) The retained portion of the scapula (S2) and the prosthesis (N-S1) matched well via the reconstruction plate shaped in advance.

[Source / Images: ‘Application of a three-dimensional printed segmental scapula prosthesis in the treatment of scapula tumors’]

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Bionic Arm Advocate Tilly Lockey Speaks at the SingularityU South Africa Summit

Last week Tilly Lockey went on stage at the Kyalami Grand Prix circuit in Johannesburg, South Africa, during the SingularityU South African (SA) Summit, for a one on one with Benji Rosman, Principal Researcher in the Mobile Intelligent Autonomous Systems group at the Council for Scientific and Industrial Research (CSIR). The no-filter, expert public speaker, activist, and model has been touring the world to talk about her incredible bionic arms. And did we forget to mention she’s only 14 years old? Her triumphant take on life is breathtaking, known for opening up about the illness responsible for the loss of both hands at a very early age, as well as her upbeat and confident attitude. Throughout the last few years, Tilly has been a massive force for children, helping prosthetic companies develop customized products suited for kids. Today she is an ambassador for Open Bionics, a UK-based firm developing low-cost bionic hands, also known as Hero Arms.

Benjamin Rosman and Tilly Lockey at the SingularityU SA Summit (Credit: SingularityU South Africa)

Tilly was one of three speakers of the Summit’s Biotech and Medicine segment, along with Habib Frost, who talked about the future of medicine and technological advancements, and Kim Hulett who discussed designer babies. Showcasing her incredibly sleek bionic arms, Tilly focused on her vision for the human-machine convergence of the future.

According to SingularityU SA, during the segment titled Benjamin Rosman in Conversation with Tilly Lockey: What’s Possible in the Future, the two examined the connection between technology and human beings.

“Think about all the things you do with your hands on a daily basis. These hands help me both physically and mentally,” said Tilly. “All the money used to go to the aesthetics of the hands, how they looked and not how they worked.”

With an estimated five million upper limb amputees globally, companies like Open Bionics are essential to build and develop the next generation of bionic limbs, in what Rosman referred to as “turning disabilities into superpowers.” Technology is not only changing how prosthetics work. Prosthetics can be heavy, which is something to keep in mind when developing bionic arms for kids. Growing up also means that hands need to be recreated and replaced at least yearly. With Open Bionics, things began to change, the company 3D prints the prosthetics from plastic, making them lightweight and more affordable, while the cost lies in the battery and the motors on the inside. A pair of 3D printed bionic arms can often reach around £10,000 (that’s roughly 12,800 dollars), which often means a lot of fundraising is involved.

“Now kids get excited when they see me. My arms look like something out of an action movie, like from Marvel. They give other kids the idea that their disability is their superpower,” suggested Tilly.

Actually, she is not so far off from the cinematic universe. Last January, she received a pair of Alita: Battle Angel bionic arms from director James Cameron. The multi-grip functionality Hero Arms were designed by the team behind the movie, and Cameron invited her to the premiere of the highly awaited sci-fi futuristic action film where she got to show everyone her brand new hands.

The Hero Arm is now available through private prosthetic clinics for people with below-elbow upper limb differences, aged nine and above. They are considered the first medically certified 3D printed bionic arm. They are engineered and manufactured in Bristol, UK, in a lightweight and affordable myoelectric prosthesis, now also available in the US and France for below-elbow amputee adults and children.

Open Bionics ensures that each Hero Arm is custom-built using 3D printing and 3D scanning technologies. They claim the prosthesis is robust, and the socket is comfortable, adjustable and breathable too, which means it’s easy to take on and off. It’s a powered bionic limb controlled by the muscles, with intuitive lifelike precision. Additionally, it consists of a breathable removable socket for enhanced ventilation and easy cleaning, powered by high-performance motors, advanced software and long-lasting batteries. The hand, which comes in three sizes, is the lightest on the market but extremely strong, able to lift up to eight kilograms.

The inspiring Tilly Lockey, who was diagnosed with meningococcal meningitis as a 15-month old baby, lost both of her arms, yet her role as a leader in the development of technology in the field of prosthetics is very important and she has been working with Open Bionics for the past four years, providing input that became fundamental in the right development of bionic limbs. Her presentation draws on her personal experience using two 3D printed, customized arms, and her role as a leader in the development of technology in this field.

Tilly at the SIngularityU South Africa Summit (Image credit: SingularityU South Africa)

Tilly revealed during the presentation that she has added a few personal tweaks to her hands, providing customization (and sometimes crazy feature) feedback, to Open Bionics over the last years. What makes Tilly’s arms different–compared to regular, humanlike prosthetics–is that they have additional modes over and above open and close. All bionic advanced prosthetic arms work differently. What’s more, is that they’re personalized in terms of sensitivity, they work on flexing and releasing muscles.

The teen is very optimistic as to what the company will be able to do in the next five years, perhaps eventually offering features like projectors, a voice assistant, Bluetooth speakers, and even Haptic Touch feedback. Up until now, the company developers have proven that they can create much more than a simple open and close bionic arm, so expectations run high.

Tilly was able to help reimagine what a prosthetic extension could look like, welcoming a future where disabilities don’t hold her back, instead they become “superpowers.” She has a lot of followers and a massive presence among young people, often admitting that she enjoys the questions many kids make about her arms. The young role model suggested that creating new interesting technology is one thing, but it also needs to address gaps in society, moving out of research labs and into everyday lives.

Tilly Lockey at the Alita: Battle Angel premiere wearing her new Hero Arms (Image credit: Open Bionics)

SingularityU SA is the first African Country Partner and seeks to work with established businesses, entrepreneurs, and future innovators to create new opportunities for innovation and impact in the country. The education giant wants to “future proof Africa” by empowering its people to create abundant, sustainable, and holistic ways of living and working.

The World Health Organization states that just one in 10 people with physical disabilities in the developing world have access to technologies that could assist them, and with over ten million amputees around the world, this is certainly an innovation we need to advance. Making prosthetics available quicker, cheaper and better can solve one of Africa and the world’s challenges.

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3D Printing News Briefs: July 2nd, 2019

We’re talking partnerships and materials in today’s 3D Printing News Briefs. The Alfa Romeo F1 team and Additive Industries are strengthening their technology partnership, while Beam-IT and SLM Solutions are expanding their own cooperation. Metallum3D just opened a new beta testing program for its stainless steel filament, while Zortrax and CRP Technology are both introducing new materials.

Alfa Romeo F1 Team and Additive Industries Strengthen Partnership

At the recent Rapid.Tech-Fabcon industrial 3D printing conference in Germany, Additive Industries announced that its current technology partnership with the F1 team of Alfa Romeo Racing would be growing stronger. The Sauber Engineering company, on behalf of Alfa Romeo Racing, has ordered an additional: 4-laser, multi-module MetalFAB1 Productivity System, bringing the total up to four systems and making it Additive Industries’ largest customer with a high-productivity metal 3D printing capacity.

Our installed base is growing fast, not only with new customers in our core markets like aerospace and the automotive industry but also through existing customers like Sauber Engineering, who are advancing to become one of the leading companies in industrial 3D printing in Europe, ramping up production,” stated Daan Kersten, the CEO of Additive Industries. “Although most users of metal additive manufacturing are still applying prototyping systems, we see an increasing number of companies concluding they need dedicated systems for series production. Our modular MetalFAB1 family is the only proven system on the market today designed for this use. We are grateful and proud to be technology partner to Sauber Engineering and the F1 team of Alfa Romeo Racing.”

Beam-IT and SLM Solutions Sign Expanded Agreement

M.Sc.Eng. Martina Riccio, AM Process Leader of Beam-IT and technical team

Italian 3D printing service bureau Beam-IT and metal 3D printing provider SLM Solutions have signed an agreement, which will expand their current long-term cooperation. Together in a joint venture project, the two will work to develop more material parameters – focusing on certain material properties – for the nickel-based alloys IN939 and IN718; this process will help create a less lengthy timeframe in terms of parameter testing. Additionally, Beam-IT has added two new SLM 3D printers to its product portfolio: an SLM 280 and an SLM 500.

 

 

 

“We are pleased to announce our cooperation agreement with SLM Solutions and the two additional machines,” said Michele Antolotti, the General Manager of Beam-IT. “We regularly produce high-quality parts for our customers using selective laser melting because the SLM ® technology works efficiently, quickly and, above all, safely. With the expanded capacity of our new multi-laser systems we can also increase our productivity and react to the increased interest in SLM ® technology from our customers.”

Metallum3D Opens Stainless Steel Filament Beta Testing Program

Virginia-based company Metallum3D announced that it has opened a beta test program for its stainless steel 316L 3D printing filament. This new program will support the company in its development of an affordable and accessible on-demand metal 3D platform for FFF 3D printers. The Filament Beta Test Program is open until July 31st, 2019, and a limited run of 150 0.5 kg spools of Metallum3D’s stainless steel 316L filament will be offered for a discounted price on a first come, first serve basis.

Nelson Zambrana, the CEO of Metallum3D, said, “Our 1.75mm Stainless Steel 316L filament material has a metal content of 91.7% by weight or 61.5% by volume, while maintaining enough flexibility for a minimum bend diameter of 95 mm (3.75 in.). The combination of high metal loading and filament flexibility was a tough material development challenge that took us over a year to solve.”

Zortrax Introducing Biocompatible Resins for Inkspire 3D Printer

Last year, Polish 3D printing solutions provider Zortrax developed the Inkspire, its first resin 3D printer. The Inkspire uses UV LCD technology to create small and precise models for the architecture, jewelry, and medical industries. With this in mind, the company is now introducing its specialized biocompatible resins that have been optimized for the Inkspire to make end use models in dentistry and prosthetics.

The new class IIa biocompatible Raydent Crown & Bridge resin is used for 3D printing temporary crowns and bridges, and is available in in an A2 shade (beige), with high abrasion resistance for permanent smooth surfaces. Class I biocompatible Raydent Surgical Guide resin for precise prosthetic surgical guides  is safe for transient contact with human tissue, and offers translucency and high dimensional accuracy. With these new materials, the Zortrax Inkspire can now be used by prosthetic laboratories for prototyping and final intraoral product fabrication.

CRP Technology Welcomes New Flame Retardant Material

Functional air conditioning piping made with LS technology and Windform FR1

In April, Italy-based CRP Technology introduced its Windform P-LINE material for for high-speed, production-grade 3D printing. Now, it’s officially welcoming another new material to its polyamide composite family – Windform FR1, the first carbon-filled flame-retardant laser sintering material to be rated V-0. The material is from the Windform TOP-LINE family, and passed the FAR 25.853 12-second vertical, the 15-second horizontal flammability tests, and the 45° Bunsen burner test. The lightweight, halogen-free material combines excellent stiffness with superior mechanical properties, and is a great choice for applications in aerospace, automotive, consumer goods, and electronics.

“Only a few days from the launch of a new range of Windform® materials, the P-LINE for HSS technology, I’m very proud to launch a new revolutionary composite material from the Windform® TOP-LINE family of materials for Laser Sintering technology,” said Franco Cevolini, VP and CTO at CRP Technology. “Our aim is to constantly produce technological breakthroughs. With Windform® FR1 we can steer you toward the proper solution for your projects.

“We will not stop here, we will continue our work on renewal and technological expansion in the field of Additive Manufacturing. Stay tuned!”

Discuss these stories and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

3D Printed Color, Soft-Tissue Maxillofacial Prosthetics Offer Many Benefits to Patients Today

Researchers Faraedon M. Zardawi and Kaida Xiao have recently published a paper, ‘Optimization of Maxillofacial Prosthesis,’ delving into anaplastology and the positive impacts of 3D printed prostheses. Here, the authors assess color, soft-tissue prosthetics fabricated on a Z Corp Z510 with Sil-25 silicone polymers.

An overview of rapid manufacturing technology applied to fabricate soft tissue facial prostheses.

While such devices may be an incredible gift for so many, the area of prosthetics is still notably rife with challenges. Comfortability and design issues are major concerns—along with affordability, ongoing size-ing for kids, and speed in manufacturing—but the patients themselves often have serious struggles in adapting to defects or sudden physical loss (as with an arm or a leg or another part of the body). It can be devastating to lose an arm or leg, or even a finger, but deformities of the face can be further distressing for patients. Self-consciousness can be overwhelming, and patients with facial disfiguration may not want to go out in public.

Facial prosthetics can be extremely helpful, but the authors point out that they are usually not able to completely restore function in exercises like chewing, for example, and surgery is usually only able to rectify small problems. It is not surprising that individuals of any age suffering from defects in the craniofacial region may become extremely depressed and embrace isolation. Medical intervention can make an enormous difference, and especially with prosthetics after such as cancer may lead to tumors requiring surgical removal—resulting in a surprising amount of disability, from vision problems to limited ability to chew.

“Prosthetic rehabilitation of these patient provides comfort to the patients, improves their confidence and self-esteem. High level of satisfaction was recorded among patients wearing facial prostheses,” state the researchers. “They experienced much better quality of life after wearing facial prostheses.”

Most devices are created via impressions, casts, and then usually wax models which translate to the final product, with matching skin tones. Current, conventional methods have proven challenging though, due to the amount of time and cost involved, not to mention ‘esthetic’ issues. Such limitations mean that accessibility and affordability in developing nations is ‘almost denied’ as only a small percentage of patients are offered facial prosthetics or can afford them.

3D printing technology, however, offers the potential to make sweeping changes—and even allows for a skin-like silicone material and the use of starch and colored ink to create skin tones. This requires great attention to the skin, however, in measuring ‘spectral reflectance,’ and developing a color profile.

Method of infiltration leaving feather edged margin of the prosthesis. (B) Flexibility of printed prosthesis infiltrated silicone polymer.

Silicone samples were tested for hardness, tensile strength, tear strength, and elongation. The researchers did note with increased hardness that the prostheses become limited in terms of flexibility. The researchers noted that most challenges with mechanical properties were due to too much starch and a lack of cohesion with the silicone polymers. They suggest further testing with multiple prototypes being printed at once to ‘compensate for the drawback in the mechanical properties’ as the prostheses that are 3D printed could have much shorter longevity—but are so affordable that it is easier to replace them.

Starch printed infiltrated silicone test samples for (A) dumbbell-shaped for tensile strength, (B) trouser-shaped for tear strength and (C) hardness test blocks.

Silicone polymers test samples for (A) dumbbell-shaped for tensile strength, (B) hardness test blocks and (C) trouser-shaped for tear strength.

Stainless steel molds for fabrication of control samples—pure silicone.

As the researchers point out, such prosthetics can also be refined and then printed out for patients ‘on-demand,’ offering incredibly customized, patient-specific care. Affordable 3D printed models may also be extremely helpful as interim devices too while patients are healing from surgeries.

“… we believe that the many limitations of handmade prostheses regarding esthetics, high prosthesis cost, time, effort, hectic impression techniques and problems of retention plus high technical skill required for fabrication by anaplastologist could be generally reduced and consequently minimizing the social and psychological challenges that often-maxillofacial patients encountered in life,” conclude the authors.

3D printing has offered massive strides not only in the medical field, but also in the realm of prosthetics. While this definitely includes many different choices today both in artificial leg and arm replacements, medical professionals are able to offer other life-changing, optimized devices that are patient-specific, including prosthetics that are made for the eyes, ears, and so much more. What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.

3D printed nasal prosthesis showing nostril opened due to controlled thickness of the prosthesis.

Nasal prostheses produced by Z510-3D color printer.

[Source / Images: Optimization of Maxillofacial Prosthesis]

US Researchers Continue to Improve 3D Printed Prosthetics for Children

US researchers from the University of Central Florida and Oregon Health and Science University have come together to review the history not only of prosthetics overall in the medical field but also to further inspect the transformation allowed by 3D printing. Contending that there are still many problems to be solved in prosthetics, the authors further explore children’s physical and emotional needs in the face of being born without or losing a limb later. Their central interest lies in new clinical trials, and in the generous—and growing—maker community.

Over 32,500 children in the US have endured amputations, according to the Centers for Disease Control and Prevention, with another 1,500 born with ‘upper-limb reductions’ annually (around 4 out of every 10,000 babies born). The authors state that many complexities arise with these limb amputations and reductions, and as a result, the use of prosthetics is still surprisingly limited. Users also tend to reject or put off applying for prosthetics due to:

  • Lack of aesthetic design
  • Weight
  • Issues with insurance or medical help
  • Lack of affordability overall

It may be hard to imagine the incredible level of self-consciousness in missing a limb—not to mention the challenges of wearing an artificial replacement in public. Because of obvious and completely understandable self-image dynamics, the researchers assert that aesthetics are a priority if users are realistically expected to wear their prosthetics long-term.

“Congenital limb loss patients are more likely to reject and forgo using a device as an adult, while females with acquired limb loss were more likely to reject devices than their male counterparts,” report the authors. “Prosthesis abandonment is a major issue in all populations and can be caused by many reasons. In the adult population, sensory feedback, appearance, function, control, comfort, and durability were all cited as key areas in need of study concerning prosthesis design and acceptance.”

Sadly, being ostracized is a very real issue, and while having a prosthetic means the potential for reducing some of the social issues, it can also have the opposite effect if it is ill-fitting or lacking enough design, both aesthetically and dynamically.

“Current trends in prostheses are to push normalization and reduce the level of stigma a user may encounter,” state the researchers.

As 3D printing has become increasingly more accessible and affordable, organizations and designers have begun working together within and outside of the US. The most well-known groups are:

The Robohand assistive device, first made available for 3D printing globally via Thingiverse. (flickr Image credit from: FDA)

Prosthetics can be completely customized and made quickly, all truly at a fraction of the cost of traditional devices. Designs for children can be fun and colorful too, allowing them to be excited about wearing their new replacement limbs, rather than approaching them with trepidation and dread.

“These devices have reached new heights of accessibility for children all over the globe, made possible due to the availability of open-source customizable designs and new 3D printers used in schools, libraries, and even residences,” explain the authors.

The Raptor reloaded hand by Enable available for download via Thingiverse. (a) Exploded view of design and user assembly methods. (b) Completed assembly of device. (Image: Thingiverse)

Creating designs and printing them out has just been the tip of the iceberg as makers have endeavored to improve the world of prosthetics. Researchers, engineers, and talented designers have been responsible for integrating electronics into 3D printed prosthetics. Jon Schull of e-NABLE was behind the creation of body-powered forearms and hands driven by actuators.

Direct user participation – for example, children working with designers – has proved invaluable for success in creating prosthetics also, with ‘higher engagement’ promoting a more positive attitude about wearing a device. The researchers, and their design team, have also been participating in work that takes a more cooperative approach for creating customized bionic limbs that are more appealing due to interchangeable sleeves. These parts can be ‘artistically customized’ through a website, allowing for comparison, selection, and personalization with color and effects.

“This early interaction is anticipated to establish an emotional connection to the limb before the participant is fitted,” state the authors.

Example interactive web page for children to customize color and effect regions during the design process, and how user participation can be translated to (Right) the final design with artistic input from art team and production teams. Sleeve design made in partnership with Riot Games.

Creating these parts includes:

  • 3D printing
  • Prepping and priming
  • Finishing, using techniques like those in the auto industry
  • Painting

“Part of the design process offers the ability for different categories or ‘empowerment classes’ of interchangeable aesthetic sleeves. These classes are broken down into four individual groups, Warrior, Shadow, Ethereal, and Serenity,” state the authors.

“These classes are designed to represent different personalities linked to emotional affinities. Artists create these inspired 3D models to connect with these personalities, and in some cases, external artists representing characters have added designs to the catalog.”

The researchers have even developed interactive video games to teach users how to wear and use their prosthetics properly. The team has also created a new clinical trial concept, meant to run for a year, proposed in partnership with University of Central Florida and Oregon Health and Science University. It is designed for children in need of prosthetics between the ages of 6 and 17 who participate in four different segments.

“The outlook for using 3D printing manufacturing techniques and collaborative design is bright, with rapidly progressing iteration and designs that can better develop affinities for users,” concluded the researchers. “At this time, limited work has been reported involving sufficient power and clinical assessment. By designing and conducting novel clinical assessment of these electromyographic 3D printed bionic limbs with well-defined outcome metrics, this may lead to being able to add to the field and better capture the readiness for broader distribution.”

The world of 3D printing is full of surprises, and you never know what might catch on and completely disrupt one niche in a field where everyone involved is accustomed to the same traditional techniques that have been ongoing for decades. The medical field is a good example—and the myriad creation of 3D printed prosthetics is an even better one, from engineering replacement limbs for veterans, to changing the lives of children in India or Sierra Leone with innovative medical devices.

3D-printed electromyographic actuated limb device with interchangeable artistic covers from Limbitless Solutions at the University of Central Florida. (a) Warrior class, (b) Ethereal class, (c) Serenity class, and (d) Shadow class.

[Source / Images (unless otherwise credited): Implementation of 3D Printing Technology in the Field of Prosthetics: Past, Present, and Future]

Case Study: A 3D Printed Patient Specific Partial Finger Prosthesis

From the University of Nebraska at Omaha, researchers Keaton Young, James E. Pierce, and James M. Zuniga explore prosthetics made via 3D printing in ‘Assessment of body-powered 3D printed partial finger prostheses: a case study.’ Here they learn more about how a hand prosthetic was able to change the quality of life for a 72-year-old man with a partial finger amputation.

Partial loss in the hand such as that of the fingers is considered to be a ‘minor amputation,’ and the authors state that this is unfortunately common; in fact, by 2050 nearly 3.6 million amputations are expected—affecting individuals and all the many tasks they need to complete daily. Many prosthetics are able to assist greatly in activities of daily living (ADLs), along with improving:

  • Psychosocial self-esteem
  • Body image
  • Interlimb coordination
  • Body symmetry

Many devices also result in ‘abandonment’ though as patients experience rejection of the device, pain due to ill fit, frustration due to inferior design, and self-consciousness if they are unhappy with aesthetics. Up to 70 percent of individuals with prosthetics report being unhappy with them. In the case study examined during this research, the individual had lost part of the index finger on his right hand. He had previously been using a titanium MCP-Driver™ finger prosthesis (NAKED Prosthetics Inc., Olympia, WA USA) with some success too—although they could be considered cost-prohibitive by some at $9,000 to $19,000. The titanium device would serve as a comparison for the one created in this study.

Research subject with amputation at the proximal interphalangeal joint of the left hand

Fittings began remotely as the debilitated area of the case study patient’s hand was scanned, along with the other non-affected hand—which served as the model for the prosthesis. The 3D printed part allows for pinch grasping—made possible by three segmented sections with simple pivot joints in between each one.

“The device was secured using a customized soft neoprene cast fitted to the palm of the hand, which was used to create an anchoring point for actuation of the device to occur and to reduce the amount of friction that the user may experience from the nylon string utilized to produced rotational force around the LFP’s interphalangeal pivot joints,” explained the authors. “A silicone grip is added onto the fingertip to increase grasp compliance and to prevent slippage of gripped objects. Initial sizing of the prosthesis was performed remotely and began by instructing the patient to photograph both the affected and unaffected limbs including a known measurable scale, such as metric grid paper.”

a Rendered CAD model of LFP. b Hand symmetry between the non-affected hand and affected hand with 3D printed finger prosthesis. c Participant performing the Box and Block Test. d Participant typing on an electronic keyboard

Parts were printed on an Ultimaker 2 extended, using PLA, including other components like a nylon string and elastic cord responsible for flexion and extension, along with padded form for a ‘soft socket’ and a protective covering to decrease friction.

Results were impressive as the patient was able to move 18 blocks per minute in the gross manual dexterity task without any prosthesis attached. With the prostheses, he could move 22 BPM—while the non-affected limb moved 30 BPM. The locally 3D printed finger prosthesis (LPF) offered similar results to the MFP device, with task-specific efficiency increased up to 73 percent. The researchers stated that this proved either the LFP or the MFP will improve dexterity for the user.

“As the accessibility to 3D printing continues to enlarge, there is great potential for 3D printing to pave the way for multiple new medical applications and devices, which may transform the fabrication process of future medical devices,” concluded the researchers.

NAKED Prosthetics Inc. MCP-Driver Finger Prosthesis

To lose functionality of a limb, suffer an amputation, or deal with a congenital defect means you have to work a lot harder than everyone else to do things they take for granted—like walking, running, grasping items, eating, playing a musical instrument, and countless other items. Designers around the world have used the advantages of 3D printing to change the lives of many, from prosthetic legs to walking sticks, devices to assist in outdoor activities, and so much more. Find out more about hand prosthetics here.

What do you think of this news? Let us know your thoughts; join the discussion of this and other 3D printing topics at 3DPrintBoard.com.

Build orientation and support generation of the 3D printed finger prosthesis

[Source / Images: ‘Assessment of body-powered 3D printed partial finger prostheses: a case study]

 

3D Printing in Africa: Kenya & 3D Printing

3D printed Kenya Flag beach shorts by SESY

Kenya has been considered to be a hub for innovation in Africa.  Personally, I started working with Kenya in 3D printing technology with a Makerbot Reseller, Amit Shah who runs Objet Kenya which is a 3D printing service provider based in Nairobi. Similar to the feelings of a first love, this is how I feel about Kenya in terms of 3D printing.

There are several other companies offering 3D printing services in Kenya and the country has a great entrepreneurial and innovative spirit. This has made 3D printing a very sensible and lovable technology and if there is something that fires it all: it is the Kenyan will to provide homegrown solutions. Kenya loves to provide their own solutions to their own problems and 3D printing suits very well in this line of thought. To add on to that, Kenyans appreciate and promote local productivity so this promotes a creative and innovative landscape where 3D printing technology makes a huge impact.

In terms of growing and developing with 3D printing technology, Kenya has been doing extremely well on this end. A 20year old electrical engineering student from Nairobi University Kenya, Alois Mbutura developed a minuscule vein finder for use with kids in the hope to address infant mortality and improve vaccination service. The minuscule vein was 3D printed using a MakerBot 3D printer.

Alenna Beroza, Kijenzi engineer, shows off some Kijenzi parts designed with and for nurse

Another great development is by the medical start-up company Kijenzi Medtech who are using 3D printing technology to provide medical solutions to Kenya’s rural clinics including very remote clinics. This is an inspiring endeavour as they assist in providing basic medical components remotely. They are also looking at training nursing staff to print components on site by simply downloading files and sending them to the printer.

Ultra Red technologies is one company in Kenya upping the 3D printing game and they have printed very interesting products like customized canopies for wildlife exploration vehicles. That’s some untapped territory in the wildlife sector in Africa and Kenya is setting the pace. On top of this, Ultra Red technologies are busy printing parts of a solar powered desalination device for providing reliable and clean water for the Kenyan populace. This will surely help to address water challenges faced in Kenya and enlighten the continent to think and pursue such solutions.

Ultra Red Outdoors 3D Printed Canopy

Kenya Connect which is an American-Kenyan not for profit organisation is offering STEM and arts classes in 3D printing to schools in partnership with US-based social enterprise Level Up Village. The drive is to promote and develop the technology at the grassroots level and create a generation that will fully harness the technology.

Micrive Infinite is integrating engineering, 3D printing technology and medical research to transform surgery, treatment and rehabilitation of patients. It is hoped that more homegrown medical solutions will help and improve healthcare in Kenya.

President Uhuru Kenyatta 3D model portrait for 3D printing

The manufacturing sector has also benefited from 3D printing. This has been enhanced with the development of Kenya’s Fab lab through the University of Nairobi Science and technology park. Kenya Fab lab was the first to bring a 3D printer into Kenya and since then they have revolutionized the technology as it has grown to the various sectors of Kenya economy. Not only that, but people in Kenya are also buying personal 3D printers for personal use and an indication of growing interest in the technology.

The innovation hub of Africa continues to develop with 3D printing. There is still great potential for 3D printing in Kenya and the good thing is that resources have been easily found to spread the technology. The future is bright for Kenya and also for Africa as a whole.

Researchers Design Fully Articulated 3D Printed Finger Prosthesis

Silicone cosmetic restoration of middle and ring finger with skin tone match to subject.

Despite the wide range of prosthetics available today, those with partial hand loss are often left out in the cold—and with a disability that often proves to be extremely challenging due to a significant loss of dexterity. Researchers from University of Colorado and Rice University aim to change that with a new design for a finger prosthesis that is fully articulated, featuring a self-contained actuator. The project and subsequent testing are detailed in their recently published paper, ‘Design and evaluation of a distally actuated powered finger prosthesis with self-contained transmission for individuals with partial hand loss.’

Using direct laser metal sintering (DMLS), the research team created a gear transmission for the medial phalanx portion of the finger. The transmission then connects with the DC motor, allowing torque transmission across the PIP joint. This new design features an automated device that is like the index finger size of a female in the 25-50th percentile. While this is an average size, in the future sizing may be possible for other amputees. For proper balance and ‘perception of the prosthesis as an external load worn on the residual limb,’ the scientists designed it with a weight like a human finger.

“The finger phalanges and underactuation mechanism form a six-bar linkage and is essentially a superposition of two four-bar linkages commonly used to underactuate two-phalanx commercial and research devices,” state the researchers. “The linkage system couples the motion of each IP joint to provide a flexion trajectory suitable for a variety of grasps used in ADL.

Testing was centered around evaluating force and flexion of the fingertips, using an Escon 24/2 controller from Maxon Motors powered at 12 V, and a Futek LSB200 load cell powered at 24 V for connecting with the fingertip at varying angles. The researchers also used a Quanser Q8-USB data acquisition board using MATLAB/Simulink to collect the following:

  • Collected load cell force
  • Motor current draw
  • Voltage

In evaluating force of the prosthetic finger, the researchers position the load cell within contact of the fingertip, while the controller powered the motor—driving the finger to the load cell. After that the researchers set up the following steps:

  1. The motor was powered for .5 seconds after detecting the impulse load.
  2. The holding force was recorded.
  3. The load cell was moved to contact the fingertip to measure the flexion speed.
  4. Flexion speed was determined by ‘dividing the time the finger took to contact the load cell from its fully extended position by the angular displacement of the finger.’

The researchers repeated the trials 15 times. As they began evaluating individual gear stages, the team realized further examination would be needed to assess contributions of the face gear pair to transmission efficiency. Mechanics of the fingers will require more validation too, along with further fatigue testing.

Fitting of Vincent finger onto patient. Note location of battery and electrodes on forearm.

 “Ongoing work on the powered finger has resulted in a more compact and higher reduction power transmission and future work will include a closer evaluation of the transmission efficiencies to determine the benefit of using face gears and the changes made to the structure of planetary gear stages,” concluded the researchers. “Alternative gearings that increase the overall reduction of the transmission while decreasing the number of gear stages necessary is of interest, in addition to a more thorough examination of the gear polishing process.

“Work will also include refinements to the residual limb attachment that better accommodates individuals with amputations distal to the MCP, as well as improvements to the robustness and anatomical motion of the kinematic link bar system. Upcoming iterations of the finger will also include improvements to its performance in opposition and safety mechanisms to protect the components in extreme or unexpected loading cases.”

3D printing has earned an honorable niche in the world of prosthetics, undeniably changing the lives of many, from prosthetics that help veterans, to amphibious limbs, to prosthetic breasts for mastectomy patients. What do you think of this news? Let us know your thoughts; join the discussion of this and other 3D printing topics at 3DPrintBoard.com.

Exploded view of medial phalanx gear transmission. Parts outlined in rectangles are the different lamina. Left and right inner laminae contain planetary stages and enclose spur/bevel gear stages housed in the central lamina. Outer laminae connect to proximal phalanx and enclose carrier pieces. Output of gear transmission connects to distal phalanx.

Rendering of the steel components of the powered finger with kinematic link bar system outlined. Dashed lines indicate that the bracket containing the links has been raised to show orientation. Bracket is grounded to proximal phalanx with two set screws at locations indicated by arrows. The hollowed plastic shells that enclose the entire finger mechanism are not shown for clarity.

[Source / Images: Design and evaluation of a distally actuated powered finger prosthesis with self-contained transmission for individuals with partial hand loss]

3D Printing in Zimbabwe

3D Printed map of Zimbabwe by makexyz

While the technology has been around for some time, 3D printing is still relatively new in Zimbabwe. Its full potential is yet to be realised, but both the young generation and enthusiastic elders are taking the step to embrace the technology. There have also been some notable applications and effort to bring the technology to light within the Zimbabwe environment. The timing is right considering a great local entrepreneurial and innovative spirit which will immensely benefit from the application of the technology.

A few companies are offering 3D printing services but they are not many. In terms of numbers, they are less than ten. Their services mainly entail basic prototyping and models for student design projects, design engineers and architects. Then there is also customized branding for corporates items like gifts, ornaments, collectibles and personalized toys for kids. Other services include maker clubs and hubs where the young generation are taught and can practise 3D printing.

Schools and technical universities are trying to include the technology as part of their activity but it’s still a journey. As part of my consultancy work in promoting the technology, I had the privilege of exhibiting the technology for the Zimbabwe STEM program so that it would be a component of the program. This exhibition took place at the Zimbabwe International Trade Fair and it was primarily a demonstration of the technology including how it works and what it produces.  I have also used the technology to develop a bottle prototype for the largest drink manufacturer in Zimbabwe, Delta beverages for their dark beer, and the bottle design was approved and currently being used for a 1.5L container in the market.

This 1.5L bottle had a 3D printed prototype done before being rolled out to market

Another very recent development in 3D printing in Zimbabwe is a local based company that is working on developing prosthetics for amputees and the disabled. One particular project is developing a prosthetic hand for a popular and well-known local footballer, Hardlife Zvirekwi who lost his hand in a car crash. The local company, Nashua Zimbabwe is currently working on this and hope to extend the service to the Zimbabwean populace.

Zimbabwe generally strives to embrace and implement new and disruptive technologies. The students will form the pillar in the drive to promote the technology in the country as they are up to date with the latest technology. That is why it is important for Zimbabwean schools to train and teach the technology for its proper application and make noble use of it. The adoption of 3D printing as part of the educational curriculum will go long a way promoting the technology. Not forgetting the hobbyists and enthusiasts who can get a fair share of exposure via industrial hubs that have been set up across the country.

3D printed mining equipment and process models for exhibition and planning

Zimbabwe is ready for 3D printing technology and it will help to create and foster an innovative, creative and inventive environment. 3D printing will help to improve Zimbabwe’s economy and solve many technical problems the country is facing. A bright future lies ahead for 3D printing business in Zimbabwe and the time is now to further tap into the full business opportunity and potential of service provision. The application areas are vast especially for Zimbabwe’s activities in manufacturing, agriculture, mining and energy, healthcare facilities and educational institutes, all of which can make use of 3D printing.

The agriculture sector will benefit from customized irrigation parts and farming equipment spares, while mining will also use 3D printing for specialized mining spares for mobile plants and also 3D printing of desktop geological and mining excavations works as a way for mine planning purposes. The energy sector will benefit from customized equipment such as hydro turbines for mini runoff river hydropower schemes which are growing popular in the country.

Zimbabwe High Resolution 3d Printing Concept

Challenges that also need to be dealt with in terms of promoting the technology is funding 3D printing businesses and services. This is still a bit of an issue as the initial cost can be high for reseller activities. Availability of funds can speed up the establishment of a 3D printing ecosystem.

3D printing will be one of the main technologies to spearhead an industrial revolution in Zimbabwe and economic driver as long as it falls into the solution-driven hands of the Zimbabwean younger generation. The technology is good to go in Zimbabwe and it’s already started to grow.

3D Printing exhibition at the Zimbabwe International Trade Fair (myself to the right)