A 3D printed prosthetic arm example design

Prosthetics are substitutes for missing limbs in the body, in particular arms and legs, but also bones, heart and arteries. There are 30 million people in need of replacement limbs, but the main challenge that people face is that prosthetics are very expensive.

According to this report, the average cost for a single prosthetic limb is around $4,500 USD and can go as high as $50,000 USD. For people in low income countries, this can be unattainable and for people in high income countries, this can be expensive. As a result, I started to think about what solutions are out there that could potentially help this cause. After some research, I came across the field of 3D printed prosthetics, which caught my eye.

What exactly are 3D printed prosthetics?

Essentially, 3D printed prosthetics involves using additive manufacturing methods such as 3D printing to create artificial limbs instead of manually manufacturing them. 3D printed prosthetics are composed mainly of plastic, just like traditional prosthetics, but can also use materials such as acrylonitrile butadiene styrene, or simply ABS, plastics, as well as bridge nylon for a stronger material.

There are 4 main types of prosthetics: transradial, transhumeral, transtibial, and transfemoral. The first 2 types are implants above and below the arm, whilst the last 2 types are implants above and below the knee. Additive manufacturing enables the fast production of these implants.

How do 3D printed prosthetics work?

3D printed prosthetics offer a more streamlined approach to the manufacturing process of prosthetics in comparison to the traditional method. There are 4 steps to this approach, with the first step being 3D scanning. This involves using medical imaging methods such as X-rays and Computerised Tomography (CT) scans to collect images of the patients broken limb.

The next step involves the images being modelled by prosthetists to create and design the required device. This is heavily influenced by the level of detail the computer software provide. The third step is the 3D printing itself, which print layers of the material to create a bonded object. This method prints lots of complex structures in a short period of time. Finally, the device made is fitted onto the patient, where the device made is designed to match the patients anatomy.

This video details the company Unlimited Tomorrow, who create prosthetic arms using 3D printing which has led to the production of their True Limb device.

Benefits and Challenges of 3D printed prosthetics

The benefits that 3D printed prosthetics provide are the reductions in the manufacturing time and costs of the prosthetics. Prosthetics produced by traditional methods often involve stringent procedures, whereas, 3D printed prosthetics offer a more step by step method which is more streamlined.

The average cost of a prosthetic arm costs around $2,000 USD, and the patient may have to wait for the prosthetic to come. Prosthetics 3D printing is more affordable in comparison, with the cost of a 3D printed prosthetic costing around $395 USD.

One challenge that 3D printed prosthetics face is in regards to material strength and durability. 3D printed prosthetics can be created by thin layers of hot plastic, which can be broken easily. Some prosthetics also incorporate materials like silicone, which can be challenging due to the limited availability of printers that can handle these materials.

The rise of 3D printing can potentially create a bright future for prosthetics thanks to the technological advances made in prosthetics design, as well as the cost efficiency, rapid production times and flexible design.