Beyond the Data Sheet in Material Science with Luke Rodgers

Send us a textDiana Hall shares her journey from chemical engineer to founder of ActivArmor, a company revolutionizing fracture care through 3D printed waterproof and breathable casts that allow patients to maintain normal hygiene and activities while healing.• Started after seeing children with wet, dirty casts who couldn't practice basic hygiene• Worked directly with FDA to develop test protocols for 3D printed medical wearables• Created a turnkey point-of-care fabrication system that clinics can operate with minimal training• Uses iPhone scanning technology for easy, accessible shape capture in under a minute• Allows custom design while maintaining standardized mechanical properties• Enables targeted immobilization that restricts only necessary joints• Popular with pro athletes, pediatric patients, and workers who need hand washing• 93% of patients choose Active Armor over traditional casts when given the option• Now used internationally by top orthopedic surgeons in 15 countriesIf you're considering innovating in the medical device space, surround yourself with experienced advisors who understand the regulatory environment—it's challenging but rewarding when you can improve patients' quality of life.Special thanks to Advanced 3D for sponsoring this episode.Support the show

Send us a textThe prosthetics and orthotics industry is witnessing significant consolidation and technological advancement, with Hanger's recent acquisition of Coapt being a prime example of this evolution.• Coapt's pattern recognition technology transforms how upper extremity amputees control prosthetic devices• Traditional myoelectric systems use only two sensors while Coapt's system employs an array of 18 sensors• Machine learning algorithms decode neurological intent, making prosthetic control more intuitive• Upper extremity amputations represent only about 20% of all amputations, creating a niche market• Blair Lock, Coapt's CEO, built the company over 13 years without outside investment• The "slow burn" approach to business growth can be necessary and beneficial in specialized medical technology• Additive manufacturing plays multiple roles in prosthetics: from prototyping to clinical fabrication• Regulatory requirements significantly impact the economics of prosthetic technology• Myoelectric technology has potential applications beyond prosthetics: exoskeletons, industrial robotics, and other human-machine interfacesSubscribe to the Prosthetics and Orthotics Podcast for more insights into the technological advancements shaping patient care.Support the show

Send us a textRuud Rouleaux, founder of ColorFabb, shares the evolution of 3D printing materials from early PLA filaments to revolutionary foaming technology that's changing prosthetic and orthotic care. His journey from plastics engineer to materials innovator reveals how focusing on functional materials rather than competing on price has positioned ColorFabb as a leader in the field.• Origins of ColorFabb in 2010 when the 3D printing market was just emerging• Development of wood-filled PLA that sparked interest in composite materials• Introduction of VarioShore foaming technology in 2016 for lightweight, comfortable devices• Creating skin-tone matched materials that can be fine-tuned by adjusting printing temperature• Obtaining compliance certifications for direct skin contact applications• Integration with advanced software like implicit modeling for better textures and geometries• Future developments including induction nozzles and better flow control• How FDM printing with the right materials sometimes outperforms more complex technologies• The shift toward data-driven approaches in orthotics while maintaining clinical expertiseSpecial Thanks to Structure for sponsoring this episode.Support the show

Send us a textDiscover the transformative world of prosthetics and 3D printing alongside Josh Pelz, co-founder of Limber Prosthetics. We delve into the intricacies of designing lightweight, integrated prosthetic devices, exploring how simplification leads to enhanced user experiences.• Introduction to additive manufacturing in prosthetics • The concept behind a single-unit prosthesis design • Importance of material testing and selection • Engineer-clinician collaboration in product development • Discussion of challenges in alignment and fitting processes • Future outlook for innovation in prosthetic technology Special thanks to Structure for sponsoring this episode.Support the show

Send us a textThis episode explores the transformative shifts in additive manufacturing within prosthetics and orthotics, highlighting key insights from the AMS conference. A focus on open manufacturing options and investor relationships underscores the challenges and opportunities for enhancing patient care in this evolving landscape. • Discussion on reflections and takeaways from AMS • Emphasis on the importance of open manufacturing systems • Insights from industry leaders about consumer demand for flexibility • Analysis of the investor's role in driving innovation • Examination of Proteor's acquisition of Filament Innovations • Exploration of the potential for global consumer markets • Reflections on the future of 3D printing in O&P Special thanks to Structure for sponsoring this episode.Support the show

Send us a textThis episode reveals how Structure Sensors are reshaping healthcare technology, emphasizing their role in improving patient care through accurate 3D scanning. Ravi Shah shares insights into the importance of collaboration and data sharing in the medical field, discussing the intricacies of their hardware, software, and the journey toward providing better solutions for clinicians.• Exploring Ravi's journey from tech to healthcare • The critical role of 3D scanning in patient outcomes • Importance of open platforms and data sharing • How Structure Sensors ensure accuracy and consistency • Practical advice for clinicians integrating 3D technology • The promise of technology in narrowing healthcare gaps • Insights into user-friendly developments for practitioners • Future aspirations for quality careSpecial thanks to Advanced 3D for sponsoring this episode.Support the show

Send us a textInnovative adjustable sockets stand to revolutionize prosthetics, promoting comfort and user satisfaction for amputees. Sydney Robinson shares her journey in creating Vessl Prosthetics, emphasizing design iterations, user feedback, and strategic positioning within the market that enable transformative solutions in limb care. • Introduction to Vessl and its mission to revolutionize prosthetic sockets • Sydney Robinson's engineering background and entry into prosthetics • The key problems with traditional prosthetics and the need for adjustability • Mechanical solution for adaptive sockets without electronics • Feedback loops from users and prosthetists for iterative design improvement • The roadmap for product launch and future plans in the market • Discussion on market consolidation versus independent practices • Importance of collaboration between engineers and clinicians in prosthetic designSpecial thanks to Advanced 3D for sponsoring this episode.Support the show

Send us a textLuke Rodgers dives into an innovative material  that offers superior resilience, affordability, and functionality compared to traditional materials. This episode highlights its unique properties, applications, and the excitement surrounding its potential impact on the industry.• Discussion of the material  • Comparison with traditional materials  • Benefits of focusing on resilience and fatigue resistance  • Applications in various industries beyond prosthetics  • How PK5000 was developed and its future commercialization plansSpecial thanks to Advanced 3D for sponsoring this episode.Support the show

Send us a textIn this episode with Elizabeth Mansfield, we explore the evolution of prosthetics and orthotics, emphasizing the influence of education, technology, and personal stories on patient care. She shares her experience and perspective, addressing current challenges and discussing the importance of engaging the next generation of professionals.• Personal stories shaping careers in O&P • Shifting educational standards from certificates to master’s programs • Importance of marketing and continuous education in O&P • Challenges in reimbursement impacting independent practices • Attracting and retaining talent in the O&P field • Integration of technology and robotics in patient care • Collaborative efforts leading to better outcomes and solutionsSpecial thanks to Advanced 3D for sponsoring this episode.Support the show

Send us a textIn this episode, we explore the transformative impact of 3D printing and CAD software in orthotics and prosthetics through the insights of guest Christiaan du Toit. Chris discusses his journey, the challenges faced in South Africa, and how effective collaboration between clinicians and designers leads to better patient outcomes.• The significance of CAD and digital tools in modern O&P • Chris's educational and professional background in orthotics • The evolution and skepticism towards 3D printing in the field • Challenges of sourcing materials and devices in South Africa • The importance of FDM and multi-jet fusion techniques • The necessity of communication for successful collaboration • Exploring future advancements in additive manufacturingSpecial thanks to Advanced 3D for sponsoring this episode.Support the show