Lightweight, individualized and inexpensive, this design and manufacturing strategy bends artificial limbs in new directions and promises a more personalized product for those in need of a replacement (or upgrade).

Developed by Adam Root, the process involves inverted laser scanning, 3D modeling and printing to generate form-fitting body parts that are comfortable, affordable and suited to a particular individual. The result is a “highly precise virtual model of the patient’s residual limb and matches its anatomy to within a fraction of a millimeter” which together with the “MIT biomechatronics lab-developed fitsocket captures leg tissue properties to enable a better fit.” Off-the-shelf parts round out these customized creations.

A custom-patterned mesh model forms the basis for fabricating an exo-skeletal structure, held together with titanium dust particles that are laser-sintered into place for strength and durability. This technique obviates the need for cumbersome central supports by spreading the loads in a sort of three-dimensional ‘space frame’, to borrow an architectural term. The resulting aesthetic is not only personalized but compelling – stylistically, it leaves choices up to the user and gives a unique look to each individual creation.

Gizmag puts these developments in context: “There are over 2 million amputees in the United States with 185,000 amputations every year. More than 90 percent of these involve amputations of the lower limbs. Traditional prostheses can be prohibitively expensive due to their complexity and the specialized labor required to customize them for each patient. They also have a very mechanical and robotic look and feel about them, which can exacerbate the sense of loss and negatively affect the psychological wellbeing of some amputees.”

Customization has long been a limiting factor in certain aspects of medical practice, particularly those centering around damaged or lost limbs  creating different person-specific needs. 3D printing technologies, perfect for one-off, fit-to-purpose projects, may just promise ideal solution(s).

Jake Evill dubs his project, Cortex, an exoskeleton rather than a cast. First, an x-ray of the injured limb is performed. Next, a scan of the exterior of that same limb is made. Finally, based on both of the above, a suitably stiff-but-flexible 3D print is made. The result is customized to the needs of the user for both recovery and comfort.

The resulting design addresses issues of aesthetics, but more importantly deals with waste, healing, safety, durability and other everyday needs. Unlike its cumbersome traditional counterparts, it is readily washable, comfortable and compact enough to fit under clothing that would otherwise require modification.

Bespoke Innovations, meanwhile, addresses the needs of those with artificial limbs through what they call Fairings. Their process likewise involves scanning the limb, but in this case of the non-organic variety, then creating a custom cover to fit the functional and stylistic needs and wants of the wearer.

From the company: “Fairings infuse the individual’s lifestyle and taste into the design from the start. But to make this an even more personal part of the prosthetic leg, Fairings can be enhanced with patterns, graphics, and materials—including leather, ballistic nylon fabric, chrome plating, and even tattoos. By creating a unique custom form that presents the individual, Bespoke Innovations hopes to change the way the world thinks of prostheses.”