Send us a text

Jochen Weigel from Stuttgart, Germany joins us to discuss his innovative contributions to prosthetics, including post-processing for Niagara feet and the development of the AirFit casting system.

• Jochen's journey from clinical specialist to R&D manager to starting his own business 13 years ago
• The AirFit system uses air pressure instead of water to create comfortable prosthetic sockets
• Air pressure uniquely compresses only soft tissue while preserving bony structures
• Testing in Kenya combined the AirFit system with low-temperature thermoplastic sockets for immediate fitting
• The Niagara foot provides exceptional durability compared to SACH feet commonly used in developing regions
• Made with special DuPont material (Hydrel) through a complex molding process few can replicate
• The foot works across weight ranges from 70-190 pounds when properly tuned
• High initial cost compared to $20 Chinese alternatives creates adoption challenges despite long-term savings
• Ways to help include volunteering with NGOs, making targeted donations, or collaborating with small companies

If you have ideas for prosthetic products that could help in developing regions, reach out to smaller companies who are more likely to be interested in humanitarian solutions.

Special thanks to Advanced 3D for sponsoring this episode.

Support the show

Send us a text

The mobile prosthetic clinic model is gaining traction as Hanger acquires Colorado-based Agile Orthopedics, potentially changing how prosthetic care is delivered nationwide. Raise3D's new RMS-220 SLS printer enters the market with open material capabilities, challenging the economics of small-scale prosthetic production.

• Mobile clinics solve transportation challenges for patients with mobility limitations
• Bringing care directly to patients is especially valuable in rural areas with weather challenges
• Centralized fabrication pairs perfectly with mobile clinical services
• Hanger could dramatically expand market reach by adding mobile clinics to existing locations
• Open-material 3D printers may help control costs when material prices increase but reimbursement doesn't
• Entry-level SLS systems face challenges with powder handling and economic viability
• Lattice structures should be used thoughtfully based on function, not just aesthetics
• Using others' designs without permission demonstrates disrespect for intellectual property

Join us next time as we continue exploring innovations in prosthetics and orthotics. Remember to subscribe to the podcast and share with colleagues who might benefit from these discussions.

Special thanks to Advanced 3D for sponsoring this episode.

Support the show

Send us a text

David Pierick, a retired Applications Engineer, shares the journey of bringing powder bed fusion technology to prosthetics and orthotics, revolutionizing patient comfort and outcomes through advanced materials.

• The initial challenge: proving 3D printed prosthetic components were as good or better than traditional methods
• Testing showed printed sockets were remarkably strong—in one test bending the aluminum testing rod before deforming the socket
• Patient feedback consistently reported greater comfort with PA-12 sockets, especially when paired with flexible interliners
• PA-11 offers superior fatigue properties and better strength-to-stiffness ratio than PA-12, though at higher cost
• PK5000 combines nylon stiffness with TPU softness, enabling thinner socket designs with excellent impact resistance
• Proper design principles are critical: avoid sharp edges, ensure proper radii on all features, and properly transition corrugations
• Future innovation requires thinking beyond traditional manufacturing constraints and adopting true 3D design approaches
• Collaborative teams of polymer experts, design specialists, and clinicians are essential for solving complex challenges
• New applications could include integrated functionality with shock absorption zones and varying flexibility in a single component

Special thanks to Advanced 3D for sponsoring this episode.

Support the show