Feb.3, 2015 | By Alec
We’ve already known for a while that 3D printing technology is perfect for making affordable prosthetics; private and collaborative initiatives (like E-NABLE) have been able to help thousands of people who have lost a limb or were born without one for just a few bucks. There’s just two problems with these prosthetics: they’re of relatively low quality and can break quite easily while, secondly, they’re hardly suitable for leg prosthetics as they cannot bear the weight.
We are therefore very interested by the approach of biomedic engineer Marco Avaro, who has developed a method of 3D printing high quality leg prosthetics at very high speeds, completing two a day. Avaro runs an orthopedic studio called Del Bene in Trieste, Northern Italy, and recently purchases an Italian-made DeltaWASP 2040 3D printer to explore 3D printed prosthetics for his patients.
Now this isn’t exactly your ordinary desktop 3D printer; not only does it have an exceptionally large print area (40 cm high), it can also print in PLA, ABS, nylon and in polymers – making it perfect for high-quality printing as well. As Avaro notes, he realized that this could be a perfect solution missing limbs. "I deeply believed in this kind of technology and when I got in contact with WASP I really found a jewel: the printer was perfect for my job."
Unlike the E-NABLE-esque hand prosthetics we can print on our own desktop 3D printers, his DeltaWASP 2040 3D printer is capable of printing single components of over 40 cm long, making it perfect for the shell that fits over the stump of the knee or thigh of his patients. And while his printer is quite expensive, he’s found that it does deliver a quality compared to traditional manufacturing techniques. "The quality is so high that I don’t have to process the plastic for the millwork," he says.
But perhaps most impressive is the incredible speed with which Marco Avaro has been 3D printing his prosthetics: "The printer is so fast; while I needed eight hours to make a tibial [lower leg] prothesis in the past, I can now do it in two."
But most importantly, these 3D printed prosthetics have proven to be very useful for his patients. As he explained, many of his patients suffer from degenerative illnesses that could lead to very asymmetric stumps. And while most traditional prostheses feature a single size, these home-made alternatives can easily be customized to ensure a perfect fit. Because of the high quality printing, esthetic results have also proven to be quite pleasing; Avaro simply polishes the finished product before delivery to make it shine.
Meanwhile, they have so far proven to be perfectly capable of supporting the patient’s weight, even when used for high-stress activities such as running and mountain climbing. This is largely possible because the layer cohesiveness of his prints is very high, spreading the weight all over the product. "DeltaWASP 20 40 prints brillantly overcame the destructive tests and the calculation tests with accomplished elements. This makes possible to realize a resistant structure which is much more lightweight," Avaro explains.
So far, the results have also been very well received by his patients: "I always observe a great satisfaction. I finish the prothesis, deliver them and there is never need for any amendment or revision. Physioterapists that follow the rehabilitation are amazed about what we do."
This initative is thus looking very promising, and suggests that there’s a larger role for 3D printers to play than simply producing low quality hand prosthetics. Perhaps industrial-grade 3D printing is the future of all prosthetic manufacturing? I’m just afraid it will take a while before insurance companies are convinced of its potential too.
Posted in 3D Printing Applications
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Hi, Did you receive my comments? see below Wonderful progress for the manufacture of a socket! What is the material used? Nylon? How come is it stronger than the other printer? Did you already tests for the resistance? Did you do a scan of the stump? What is the software you used for the rectification of the positive (negative)? How do you determine the thickness of the socket? Thanks a lot, and congratulations! Jerome Canicave Could you answer my questions, please? Thanks a lot. e-mail: canicave@yahoo.fr
Jerome Canicave wrote at 2/10/2015 9:15:07 AM:
Wonderful progress for the manufacture of a socket! What is the material used? Nylon? How come is it stronger than the other printer? Did you already tests for the resistance? Did you do a scan of the stump? What is the software you used for the rectification of the positive (negative)? How do you determine the thickness of the socket? Thanks a lot, and congratulations! Jerome Canicave
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