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DiveDesign & Bionic Pets: 3D Printing Custom Prosthetics for Dogs, Ducks, and More

New Jersey product development studio DiveDesign helps clients strategically build brands and products that will shape their industries, offering services such as industrial design, web development, engineering, design research and strategy, and prototyping. Recently, the studio’s co-founder and designer Adam Hecht reached out to us with an awesome feel-good story that involves using 3D printing and scanning to make prosthetics for animals.

Hecht told us about one of DiveDesign’s clients, Virginia-based Bionic Pets, which is one of the leading custom prosthetics and orthotics builders for animals around the globe.

“Bionic Pets is passionate about developing medical products that help animals lead better lives,” the website states. “Since the founding of the company, Bionic Pets has helped over 25,000 animals, and we’re just getting started. It is our mission to revolutionize rehabilitation and pain management in the animal world.”

Founder Derrick Campana began building orthotic and prosthetic devices for people in 2002, and started Animal Ortho Care three years later, after successfully making such a device for a dog in 2004. Bionic Pets was split into its own business when Animal Ortho Care kept growing.

Now, Bionic Pets offers custom prosthetics for, as the website states, “a variety of injuries and chronic conditions,” along with custom-fit braces and accessories, such as replacement straps and padding, a casting kit, and a KnitRite sock to be worn under the devices.

Hecht told 3DPrint.com that the Bionic Pets team makes custom prosthetic and orthotic devices for all kinds of animals, “from elephants, to dogs and even birds.”

“One of their popular dog prosthetic offerings is a full limb prosthesis for dogs who have had an entire front limb removed,” he explained. “These prosthetics are important because they take the strain off the dog’s good front leg. Without the prosthetic dogs are at a much greater risk for joint deterioration and injury.”

(Image: Bionic Pets)

To make a dog prosthetic using conventional methods of manufacturing, Campana would take a mold of the canine patient in order to fabricate a custom vest that would serve to mount the custom limb.

Adam Hecht

“However, making this type of prosthetic by hand is quite the process, requiring pouring and shaping plaster molds, forming thermoplastics, cutting, sanding, etc, adding up to nearly 15 hours of Derricks time per full limb prosthetic! Because of this, Derrick had to turn many dogs down as he simply could not keep up,” Hecht told us.

“After connecting with Derrick and learning of his challenges, we knew we had the team and resources to re-imagine this process with digital tools.”

DiveDesign collaborated with 3D digital design firm LANDAU Design+Technology to come up with a new prosthetic-making process that consisted of just four steps, starting with 3D scanning the mold of the limb. The data is uploaded to a computer, and the company uses a proprietary algorithm to generate the prosthetic from the scan, along with its mounting points, pattern, thicknesses, and more.

The DiveDesign team with Derrick Campana of Bionic Pets and Chris Landau of Landau Design after a day of filming for Derrick’s new show, Wizard of Paws.

“Then, we print it overnight out of TPU, on a large format FDM 3D printer. And finally, we screw the leg on and ship it out,” Hecht says. “This process cuts the 15 hours of handwork into an hour or so of prep and assembly, greatly increasing Bionic Pet’s capacity to help more animals than ever before.”

Hecht said DiveDesign has shipped out more than thirty 3D printed prosthetics in two months to Bionic Pets, “with many more on the way.”

Derrick Campana

Campana is also hosting his own TV show now, called The Wizard of Paws, which follows him as he travels around the US to provide life-saving, custom prosthetics and orthotics to animals in need. Recently, he visited the DiveDesign studio for an episode, and they worked together to build a 3D printed prosthetic for doggie Instagram star TurboRoo, a chihuahua we at 3DPrint.com are already familiar with due to his teeny 3D printed cart. You can check out the episode here; the DiveDesign team comes in at the 17:50 mark.

Hecht told us that the DiveDesign team “also made a 3D printed duck prosthetic for another episode (first 12 minutes or so)  tears were shed for this one!”

I am not ashamed to admit that I teared up a little watching Waddles the duck take his first steps on his new 3D printed prosthetic. There are few things I love more in my job than hearing about the many ways that 3D printing makes a positive difference in lives of both people and animals.

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

(Images: DiveDesign, unless otherwise noted)

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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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Operation Namaste Making 3D Printed Molds for Prosthetic Aligners in Nepal

Last January, Certified Prosthetist-Orthotist (CPO) Jeff Erenstone, the Chief Technology Officer of Create O&P, decided to leave the company he co-founded in order to continue advancing and improving clinical and prosthetic care in the developing world.

Jeff Erenstone fitting a prosthetic liner on an amputee’s leg

In addition to treating patients in his upstate New York clinics, he has now focused all of his attention on Operation Namaste, the non-profit organization he co-founded that is working to ensure amputees around the world have easy access to comfortable prosthetic care.

According to the organization’s website, it helps “determined people achieve by providing tools and support to Orthotic and Prosthetic practitioners in Nepal and beyond.”

Operation Namaste has worked on several helpful projects, such as hosting a summit on prosthetics and orthotics, setting up Camp Namaste for Nepalese children with limb differences, helping a Paralympic hopeful play basketball, and completing the Nepal Warrior Trek, where a team of amputees and business owners traveled to the country to raise awareness and financial assistance for victims of the 2015 Nepal earthquake.

Its latest project is SILC (silicone interface liner comfort) Solutions, which is a system for fabricating silicone liners locally. In October, Operation Namaste volunteers took a trip to Kathmandu, Nepal to test out the new program, which will work to improve prosthetic care – using 3D printing – in developing countries.

“Part service trip and part trek, this trip featured a team of prosthetists, a physiotherapist, and an amputee peer counselor who toured the beautiful country of Nepal, visiting several prosthetic clinics along the way and putting on an educational summit for Nepali practitioners discussing the latest care techniques,” the website stated about the organization’s Nepal Trek 2019.

Prosthetic liners go between an amputee and their prosthesis in order to increase mobility and comfort…which is great for patients in high-income countries with either medical insurance or the money to pay for them.

SILC Solutions prosthetic liner

Erenstone said, “Without prosthetic liners, amputees would not be summiting the Himalayas, returning to active-duty military service, and competing against able-bodied athletes in Olympic sports.”

Unfortunately, these liners are not readily available, or are too expensive, for most amputees in low-income, developing countries like Nepal.

Demonstration at educational conference in Nepal

Operation Namaste’s new SILC Solutions method uses CAD-designed, 3D printed molds to create standard-sized silicone liners. Compared to typical liners, which can cost upwards of $200, the sustainable ones created by the organization will cost less than $50 to fabricate – making them far more accessible to amputees in developing countries.

Erenstone mixing silicone to make a liner in Nepal

Erenstone has firsthand experience in seeing the positive difference that a quality prosthetic liner can make in the life of an amputee, especially in places like Nepal.

“I’m really excited for this project take off in Nepal, and beyond. Our goal here was to make liners affordable, accessible, and sustainable, and I think we are achieving that,” said Erenstone.

ROMP (Range of Motion Project), a Colorado-based nonprofit organization with dovetailing goals, is partnering with Operation Namaste to help achieve the goal of improving prosthetic care all around the world.

“Gel liners are just not within reach for most people in developing countries,” said Eric Neufeld, the chair of the board at ROMP. “This has been a limiting factor in the quality of care for amputees.”

3D printed liner mold

During Operation Namaste’s recent trip to Nepal, the team of volunteers successfully tested out the new SILC Solutions program, determining that it was possible to use 3D printed molds to make lower cost prosthetics anywhere. The organization plans to finalize its SILC prosthetic liners ahead of another planned trip to Nepal in spring 2020, where volunteers will deliver necessary materials to fabricate the liners and train practitioners on the process.

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

[Images: Operation Namaste]

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Turkish Man Helps Injured Eagle Return to the Skies with 3D Printed Prosthetic Foot

Debbie Harry the Chicken

Some of the most heartwarming stories we get to write are the ones where an animal gets a new lease on life thanks to a 3D printed prosthetic. The veterinary field has definitely been increasing its use of the technology over the last few years, and all sorts of animals, from dogs, cats, and goats to turtles, lizards and birds, have been the lucky recipients of various 3D printed prosthetic limbs, beaks, and other medical devices.

However, based on the evidence at hand (all of the stories we publish), it seems to me that our feathered friends have been receiving the most 3D printed assistance. In just the last six months, Gumpy the seagull, a baby chick and an adult chicken, a beautiful peacock, and a lucky duck named Peg each received new 3D printed feet or legs. Over the years, multiple other birds, from a macaw, a crane, and a duck to a cockatoo, a toucan and an eagle, have an increased quality of life due to 3D printed bills and beaks, which birds require to drink, eat, preen, build nests, feed their young, and complete other necessary tasks to survive.

While it’s true that most of these 3D printed animal prosthetics come from veterinarians and animal hospitals, sometimes people without a medical degree are the ones who spend their time and energy helping injured animals. Two years ago, 16-year-old Nikita Krishnan learned 3D printing and CAD skills and set up her own nonprofit, all so she could design and fit 3D printed prostheses and splints to injured animals at no cost. 23-year-old Hasan Kızıl, a resident of Derik village in the Mardin province of southeastern Turkey is also one of these amazing animal saviours.

Mardin province of Turkey [Image: TUBS, Wikimedia Commons]

Kızıl is known by the locals around town as “the life repairer,” as he creates his own makeshift prosthetic limbs and walkers for injured animals for free. He said that he’s treated close to 300 disabled animals so far, and his most recent patient was an eagle, a species of bird that has received 3D printed medical assistance in the past. A child brought the eagle to Kızıl after finding it in, as the Daily Sabah Turkey put it, “an exhausted state.”

After an examination, he realized that the eagle was missing the claws on one of its feet, which meant that it would not be able to fly.

Kızıl explained, “Eagles take off with support from their feet and the eagle was not able to fly as it couldn’t take off without a foot.”

[Image: Daily Sabah Turkey]

Kızıl said that an electric fence was the culprit behind its missing claws. So he set out to help the eagle and decided to use 3D printing to create a prosthetic limb. After plenty of calculations and modelling work, Kızıl was successful in his efforts…for which it seems the great bird was very grateful. Not long after the eagle received its 3D printed prosthetic, it started trying to take off into flight; after several tries, it succeeded and flew off.

While eagles don’t generally stick around to say thank you, Kızıl said he was happy to help it get back to the skies again. But there are others who appreciate his efforts – this March, he was the proud recipient of a Benevolence Award by Turkey’s Presidency of Religious Affairs for his continued efforts and hard work helping to treat and save the lives of disabled animals. President Recep Tayyip Erdoğan presented him with the award.

Do you know of any other 3D printed animal prosthetic stories? Let us know! Discuss this and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the comments below.