From Injury To Innovation: Building A Practical Myoelectric Hand with Ryan Saavedra

Send us a textWe share a personal update and then dive into how injuries, curiosity, and tough feedback shaped a modular myoelectric hand that is lighter, repairable in minutes, and priced for wider access. Ryan Saavedra of Alt-Bionics walks through additive manufacturing choices, PDAC approval, and a roadmap linking prosthetics with humanoid robotics.• user and clinician pain points shaping design choices • modular finger architecture for fast field repairs • nylon 12 and MJF for strength, weight, and cost • tolerancing to reduce lash and improve reliability • pricing philosophy, PDAC approval, and reimbursement nuance • EMG control foundations, firmware over AI for stability • balancing service bureaus vs in-house manufacturing • funding from bootstrap to mission-aligned investors • product roadmap focused on hands and higher DoF • cross-pollination between prosthetics and roboticsSpecial thanks to Advanced 3D for sponsoring this episode.Support the show

Send us a textWhat if everything we think we know about human walking is oversimplified?In this episode, we sit down with Dr. Steven Gard a biomedical engineer and leading gait researcher.  We unpack the real biomechanics behind prosthetic design. From artificial heart labs to O&P innovation, Dr. Gard shares surprising insights on:Why shock absorption and “energy return” don’t always behave the way prosthetic marketing suggestsHow soft tissue acts as a natural spring, changing everything about how force is transmitted through a limbThe ongoing debate between ischial containment, subischial, and elevated vacuum sockets — and why no design is one-size-fits-allWhere microprocessor knees and 3D printing fit into the future of mobilityThe missing link between engineering theory and clinical practiceWhether you’re a clinician, researcher, or just prosthetics-curious — this episode reframes gait in a way you’ve never heard before.Special thanks to Advanced 3D for sponsoring this episode.Support the show

Send us a textCredit card rewards expert Colin Stroud reveals how O&P practice owners can transform regular business expenses into valuable rewards through strategic credit card usage. He explains the mechanics behind credit card rewards systems and how business owners can maximize returns on spending they would do anyway.• Single practitioner O&P clinics typically spend $15,000-$20,000 monthly on components• Larger clinics can spend $100,000-$200,000 monthly, generating substantial reward potential• Credit cards offer both cash flow advantages and rewards generation simultaneously• Cash back options typically max out at 2-2.5% return on spending• Points-based flexible currencies can yield 5%+ returns when redeemed strategically for travel• Rewards are considered rebates rather than taxable income• Multi-owner practices can divide points proportionally among partners• LinkedIn content marketing has driven Colin's entire business growth without paid advertising• The "arbitrage opportunity" of points redemption delivers significantly higher value than cash backVisit Colin on LinkedIn (Colin Stroud - with one L) or at gosomewhereworld.com to access his free newsletter and guides on maximizing credit card rewards.Special thanks to Advanced 3D for sponsoring this episode.Support the show

Send us a textBrent Wright shares his experiences from the American Orthotic and Prosthetic Association (AOPA) conference, highlighting innovations in 3D printing, data-driven technologies, and revealing his groundbreaking polar printer project for prosthetic sockets.• AOPA attendance exceeded 2,000 people with 165 exhibitors including 30 new vendors• Digital Showcase featured case studies for prostheses and orthoses using scanning technology• Blasingtech impressed with 3D printing capabilities, producing foot orthoses in 30 minutes• AI-designed scoliosis braces are outperforming experienced clinicians with better correction angles• Radii's socket design algorithms now match skilled clinicians in patient comfort and feedback• Tennr software helps clinicians identify missing documentation needed for insurance approval• Brent reveals the "Vortex" - a polar printer with non-planar toolpaths creating sockets in under 2 hours• Non-planar polar printing produces significantly stronger sockets than traditional layer printing• Vortex printers are already in production with three units being prepared for clinical testingSpecial thanks to Advanced 3D for sponsoring this episode!If you are interested in the Vortex DS1 please follow this link: Vortex DS1 3D Printer - Advanced 3DSupport the show

Send us a textWe catch up with Niles from Leonard Industries, our first-ever returning guest, as he reveals game-changing innovations in prosthetic and orthotic fabrication technology. This episode explores how new manufacturing tools are making fabrication faster, safer, and more consistent while helping address the industry's technical workforce challenges.• Leonard Industries has expanded by acquiring a machine shop with enhanced capabilities• Their revolutionary Wave Oven cuts heating time from 20 to 7 minutes using targeted infrared technology• The oven creates consistent results with wider work windows, eliminating the need to flip materials• Safety innovations include emergency stops, magnetic starters, and controlled heating• Multiple oven models accommodate different fabrication needs, from standard to large KFO applications• The "toast test" demonstrates heating consistency by showing how evenly bread slices brown• Leonard Industries will showcase their technology at the upcoming AOPA conference• The company has helped establish safer educational environments at O&P schools• Niles emphasizes making fabrication more accessible to new technicians through consistency and automation• Their aluminum construction ovens use less energy while providing more precise heating controlVisit the Leonard Industries booth at AOPA to see live demonstrations of their new fabrication technology, including the Wave Oven, dust collection systems, and fume extractors.Special thanks to Advanced 3D for sponsoring this episode.Support the show

Send us a textWe preview the upcoming AOPA National Assembly in Orlando, discussing what makes this prosthetics and orthotics trade show valuable for professionals across the industry.• AOPA (American Orthotic and Prosthetic Association) National Assembly happening September 3-6 in Orlando, Florida• 165+ exhibitors representing various aspects of the O&P industry • Educational tracks covering clinical, technical, business, and pedorthic topics• Up to 34 continuing education credits available in person, with 100+ hours of online content afterward• Hands-on technical laboratory for fabrication techniques and safety equipment demonstrations• Digital Showcase featuring case studies and workflow solutions from different vendors• Administrative Law Judge mock trial simulating insurance appeal processes• Strong 3D printing presence with 33+ companies showcasing additive manufacturing solutions• Notable exhibitors including long-established companies and first-time participants• Importance of consistency at trade shows for building relationships and trust in the industry• Networking opportunities that facilitate business connections and partnershipsJoin us at the Prosthetics and Orthotics Podcast booth where we'll be broadcasting live throughout the event!Special thanks to Advanced 3D for sponsoring this episode.Support the show

Send us a textBrad Matear, who oversees central fabrication for Shriners Children's hospitals, shares insights on the technical side of O&P, highlighting the critical shortage of trained technicians and pathways for advancing the profession.• Shriners Children's central fabrication serves approximately 19 facilities nationwide, dealing with complex pediatric cases that require exceptional technical skill• The field faces a serious technical talent shortage with 15-16 clinical schools but only 4 technical schools producing graduates• Technician compensation and recognition are crucial factors in retention, with approximately 30% attrition rate compared to clinicians• Digital fabrication including CAD/CAM and 3D printing represents the future for technicians, requiring new educational approaches• The Assistant Credential offers a promising middle path between technical and clinical roles, similar to the PT/PTA model• Technical education must evolve to include both traditional hand skills and advanced digital techniques• AOPA 2025 in Orlando will feature hands-on technical education including custom fabrication and alignment techniques• Proper disposal and recycling of materials remains a challenge, particularly for foam products used in fabricationPlease recycle your plastics as best you can and if you're an engineer with ideas for recycling carving foam, the industry needs your solutions to reduce landfill waste.Special thanks to Advanced 3D for sponsoring this episode.Support the show

Send us a textRich Dubin, CEO of LER Expo, shares his journey creating digital educational platforms that foster cross-disciplinary learning for healthcare professionals in the lower extremity market. We discuss how bringing together specialists from different fields—from podiatry to orthotics and prosthetics—leads to better patient outcomes and more innovative approaches to care.• Founded LER Expo in 2019, perfectly timed before COVID shut down in-person educational events• Created an engaging digital conference platform that recreates the in-person experience with lobbies, exhibit halls, and networking spaces• Uses innovative approaches like tournament-style presentations to keep audience engagement high• Emphasizes the importance of cross-disciplinary education across healthcare specialties• Discusses concerns about the rising cost of O&P education with master's programs approaching $200,000 in total costs• Highlights the critical value of mentorship and hands-on experience versus academic credentials alone• Shares practical advice for clinicians wanting to present at virtual conferences• Believes collaborative care across disciplines leads to better outcomes for patients• Encourages professionals to look beyond their specialty silos to find new connections and innovationsSpecial thanks to Advanced 3D for sponsoring this episode.Support the show

Send us a textWe explore the exciting intersection of engineering, biomechanics, and 3D printing in prosthetics with our guest Ashton Stoop, who shares his journey from mechanical engineering student to designing 3D-printed prosthetic limbs in Mexico.• Ashton's background in mechanical engineering and his path to O&P through biomechanics research• The importance of both functionality and emotional integration in prosthetic design• How custom prosthetic covers serve as tools for patient acceptance and identity• Using Rhino and Grasshopper software to create automated workflows for socket design• The balance between maintaining clinical control and leveraging AI automation• The potential for 3D printing to democratize the prosthetics industry• How small clinics can compete with larger corporations through innovative technology• The critical importance of clinical evaluation and fitting despite technological advances• Challenges in biomechanical understanding of complex structures like feet and ankles• Community initiatives like the Digital Limb Collective that share knowledge and best practicesThe field of prosthetics needs professionals from all backgrounds – you don't have to be a clinician to make a difference in people's lives. If you have design skills and a passion to help others, there is room for you to contribute to this meaningful work.Special Thanks to Advanced 3D for sponsoring this episode.Support the show

Send us a textDhruv Agrawal, founder of Aether Biomedical, shares how a birthday gift 3D printer led him from medical school to developing the Zeus hand, the strongest bionic prosthetic hand on the market with revolutionary cloud-based tracking capabilities.• Journey from medical student to prosthetics innovator began with a 3D printer birthday gift• Uses additive manufacturing not just for prototyping but for actual production components• Zeus hand features industry-leading grip strength and 30-minute repair capability• Cloud-based platform tracks usage data, showing super users complete 700-800 grip cycles daily• Data collected helps optimize device settings and provides evidence for insurance authorization• Most users rely on 4-6 standard grips plus 2-3 customized grips for specific activities• Currently working on multiple versions of the Zeus hand at different price points• Long-term vision is to become "the operating system for assistive devices" across prosthetics, orthotics, and exoskeletons• Company of 60 people with half dedicated to research and development• Future developments include VR training tools for phantom limb pain managementSpecial thanks to Advanced 3D for sponsoring this episode.Support the show