Wilmington Robotic Exoskeleton Allows Those Affected with Disease to Move Easier

Many people who are affected by neuromuscular diseases like muscular dystrophy are unable to build the strength they need to perform everyday tasks.  This can be especially difficult for children with these conditions, because they can’t learn to do these types of tasks on their own.  Using 3D printing, however, it is possible to help them perform many of these types of actions.

3D printers are now able to create a system that attaches to the individual to give them additional strength and control.  The Wilmington Robotic Exoskeleton, or WREX as it is called, doesn’t require a battery or power source.  It operates using custom rubber bands that simply add strength to the individual’s body.

The exoskeleton attaches to the arms and shoulders, and then uses the tension from rubber bands to allow patients to more easily control their movements.  The system can be 3D printed in under a day, and designed to fit perfectly on the patient, which makes them much more effective than would otherwise be possible.

Tariq Rahman, PHD and Senior Research Engineer at DuPont Hospital for Children said, “If you do the geometry right and you put the bands in the correct place, you can get this floating sensation for a kid.” 

The added strength and control of this device will not only provide the immediate quality of life improvements that are so important for children and adults, but will also help encourage additional exercise and building of strength. 

You can see a video of a little girl who is benefiting from the WREX system by clicking HERE.

Foot Problems? 3D Printing Custom Shoes Coming Soon

A San Diego start-up called “Feetz” is working hard to solve the problem of sore feet, and even some leg or back issues, by putting the 3D printing technology to work printing shoes.  They have a system where people can take three pictures of each foot, from specific angles, and upload them to the Feetz system.  The company will then print off shoes that fit perfectly, thus providing for a much more comfortable fit.

In the future, the company would want to expand to also offer 3D printed shoes to everyone, whether or not they have foot problems.  The CEO of the company, Lucy Beard, said of the company, “So many people have feet problems because one foot is bigger than the other or the shoes just don’t fit their feet right.  But if you print a shoe just for that foot, it’s going to be so comfortable, you’re not going to want to take it off.”

She went on to say, “I want to solve that need and that pain for those people.  3D-printing shoes for them is really a simple solution that could solve a lot of other problems.”  Using a variety of materials, it will be possible for the company to create durable shoes that are comfortable to wear, and even look quite nice.

As the 3D printing technology advances, the company will likely be able to offer a much wider variety of looks to their shoes as well, which will attract many people who want unique looking shoes.  Some ideas that come to mind right away include sports teams that could have their shoes custom printed to all match their uniforms, while also providing the proper support and comfort that they need.  Fashion experts could also use the technology to print off great looking shoes that not only look amazing, but also feel great too.

Major companies like Nike and Adidas are already using 3D printing to create certain parts of their shoes, but building an entire shoe from the printer is a big step forward.  It opens up a lot of possibilities.  If Feetz is successful, this could bring about a major change in the way shoes are made in the future.

Doctors Use 3D Printer to Print Custom Titanium Pelvis for Patient

A patient who had chondrosarcoma, a form of bone cancer that does not respond to drugs or radiotherapy, had to have half of his pelvis removed in order to take out the cancer.  Due to the amount of bone that was removed, it would have been difficult to successfully fit him with a traditional implant.  Doctors said that with so much bone removed, there was not enough left with which an implant could be attached.

This would have left the leg attached to the body only by muscle and skin, and completely detached from the spine, essentially making it useless.  In all likelihood, the patient would have had to have his leg amputated as well as losing half of the pelvis bone.  Fortunately, Doctor Craig Gerrand came up with the idea of using 3D printers to avoid this problem.

Scans were taken of the patient’s pelvis so doctors would know exactly how much bone needed to be removed.  Using those scans, they were able to use 3D printing technology to ‘print’ the replacement to the exact specifications of the bone that was being removed.   The printer used successive layers of titanium powder, which was fused together by a laser.

Once the replacement was completed, it was coated with a mineral, which the remaining bone could grow, resulting in a long lasting replacement with fewer problems.

The medical team worked with Stanmore Implants, the company that had the advanced 3D Printer, to print the precise replacement.  The 12 hour surgery was successful, and the patient can now walk with a cane.  With time, he may be able to walk without the cane. 

3D Printing Key Tool in Successful Skull Surgery on 6-Month-Old Child

A 6-month-old child who was born with a congenital skull deformity known as plagiocephaly harnessed the power of 3D printing and virtual planning to help improve the surgery that they would have to perform.  The deformity causes one of the growth plates of the skull to fuse prematurely.  The result is a flattened forehead on one side, and a prominence of the other side.  It also typically causes orbital asymmetry.

The team of surgeons from Stony Brook University, which is led by Dr. Michael Egnor (Professor of Neurosurgery) and Dr. Elliot B. Duboys (Associate Professor of Plastic Surgery) used Computerized Assisted Design to take the images from a CAT scan and create virtual models as well as a 3D model of the skull. 

They then planned out the surgery virtually so they would have a much better idea of what to expect when they actually did the surgery.  In addition, they were able to use the virtual data to 3D print the results of the surgery, so they would know exactly what they would need to do in order to get the results they wanted.

The surgery was performed successfully using these models, and the Doctors have said that the procedure was shortened significantly because of their preparations using the 3D printed model and virtual practice.  The child is doing extremely well post-surgery.

3D printing and other advanced technologies like this are helping doctors prepare for surgeries in ways that were not possible a short time ago.  By having a very precise representation of the patient, doctors experience far fewer complications and unexpected events, which can dramatically improve the outcomes.  

Doctors Use 3D Printer to Print Custom Titanium Pelvis for Patient

A patient who had chondrosarcoma, a form of bone cancer that does not respond to drugs or radiotherapy, had to have half of his pelvis removed in order to take out the cancer.  Due to the amount of bone that was removed, it would have been difficult to successfully fit him with a traditional implant.  Doctors said that with so much bone removed, there was not enough left with which an implant could be attached.

This would have left the leg attached to the body only by muscle and skin, and completely detached from the spine, essentially making it useless.  In all likelihood, the patient would have had to have his leg amputated as well as losing half of the pelvis bone.  Fortunately, Doctor Craig Gerrand came up with the idea of using 3D printers to avoid this problem.

Scans were taken of the patient’s pelvis so doctors would know exactly how much bone needed to be removed.  Using those scans, they were able to use 3D printing technology to ‘print’ the replacement to the exact specifications of the bone that was being removed.   The printer used successive layers of titanium powder, which was fused together by a laser.

Once the replacement was completed, it was coated with a mineral, which the remaining bone could grow, resulting in a long lasting replacement with fewer problems.

The medical team worked with Stanmore Implants, the company that had the advanced 3D Printer, to print the precise replacement.  The 12 hour surgery was successful, and the patient can now walk with a cane.  With time, he may be able to walk without the cane. 

3D Printing Key Tool in Successful Skull Surgery on 6-Month-Old Child

A 6-month-old child who was born with a congenital skull deformity known as plagiocephaly harnessed the power of 3D printing and virtual planning to help improve the surgery that they would have to perform.  The deformity causes one of the growth plates of the skull to fuse prematurely.  The result is a flattened forehead on one side, and a prominence of the other side.  It also typically causes orbital asymmetry.

The team of surgeons from Stony Brook University, which is led by Dr. Michael Egnor (Professor of Neurosurgery) and Dr. Elliot B. Duboys (Associate Professor of Plastic Surgery) used Computerized Assisted Design to take the images from a CAT scan and create virtual models as well as a 3D model of the skull. 

They then planned out the surgery virtually so they would have a much better idea of what to expect when they actually did the surgery.  In addition, they were able to use the virtual data to 3D print the results of the surgery, so they would know exactly what they would need to do in order to get the results they wanted.

The surgery was performed successfully using these models, and the Doctors have said that the procedure was shortened significantly because of their preparations using the 3D printed model and virtual practice.  The child is doing extremely well post-surgery.

3D printing and other advanced technologies like this are helping doctors prepare for surgeries in ways that were not possible a short time ago.  By having a very precise representation of the patient, doctors experience far fewer complications  and unexpected events, which can dramatically improve the outcomes.  

European Space Agency Working on 3D Printing Moon Structures

FINALLY!  Ever since I’ve been interested in 3D printing I have said that we should use this technology to improve space research.  The European Space Agency (ESA) has been working with a London-based architectural firm, Foster & Partners, to test out the feasibility of using a 3D printer to create structures in space. 

The firm has taken the concept to a whole new level, which may make it FAR more practical to build structures on the moon in the very near future.  They are working on a 3D printer that will use local moon soil rather than the normal thermoplastic or other materials that are found on the Earth.  This will dramatically reduce the amount of materials that need to be shuttled from the Earth to the Moon for construction, which means it is much more affordable.

The scientists working on the project are testing a robotic printer that is on a motorized rover.  It will print over an inflatable dome, which will be the base.  The design they are working on now will house four people.

It is a weight-bearing catenary dome, with cellular structured walls.  These walls are designed to shield the occupants against micrometeoroids, as well as space radiation.   

The 3D printer itself was developed by Enrico Dini, who says “Our current printer builds at a rate of around 2 meters per hours, while our next-generation design should reach 3.5 meters per hour.  We can complete an entire building in a week.” 

Imagine for a moment the practical applications here.  Sending a 3D printer up to the moon to begin creating structures that can house 4 people each.  Since it is using the sand that is already on the moon, you don’t have to keep sending the extremely heavy building materials.  It can be solar powered, so that won’t be an issue either.  *If I’m a hotel owner, I’m salivating at the tourism opportunities for the next 15-20 years!*

The lunar sand can be ‘printed’ into place, and then hardened into place using a binding salt.  This salt makes the sand as hard as stone, which is important for keeping the structure safe.  

This is currently being tested inside a vacuum chamber, where they are already successfully printing various wall sections. 

What do you think about this incredible technology?  Post in the comments below. 

Hershey’s Chocolate to deliver 3D printed Snacks

Well, I suppose it was only a matter of time. Hershey’s will be using 3D printing technology to print off custom chocolates and other snacks for their customers.  They entered into a multi-year contract with 3D systems to develop this technology so it can be used to make a wide range of different types of custom snacks.

William Papa, Vice President and Chief Research and Development Officer of the Hershey Company said, “We believe that innovation is key to delivering relevant, compelling consumer experiences with our iconic brands.  Whether it’s creating a whole new form of candy or developing a new way to produce it, we embrace new technologies such as 3D printing as a way to keep moving our timeless confectionery treats into the future.”

It won’t take much to think of what types of things this will be used for.  The first thing that comes to my mind is wedding cake toppers.  Imagine printing off chocolate toppers that look just like the bride and groom.   How fun!  Also, Valentine’s Day can be taken to a whole new level with creative chocolates that are customized to that special someone. 

There is no shortage of things that people will think of, and if Hershey’s can perfect this service and start offering it before other companies, they will be well positioned to eat up the market (pardon the pun). 

Chuck Hull, Chief Technology Officer of 3D Systems said, “Mainstreaming 3D printing is fundamental to our success and we are fortunate to partner with Hershey, the largest producer of quality chocolate in North America and a global leader in chocolate and confection to expand the 3D printing experience into delectable edibles.”

I know I will be looking forward to enjoying some delicious 3D printed chocolate.  How about you? 

US Company Creates First multi-Colored 3D Printer

Stratasys has announced that they have created a 3D printer that can use multiple materials, and print in full color.  It is able to create hard, soft and flexible objects using a variety of different polymers, and can create them in a rainbow of colors.  The trick, they say, was their triple-jetting technology that combines small drops of three base materials, which helps to reduce the need for painting and separate runs.

Being able to create something that can basically be packaged and sold right after printing is going to be a huge time saver for companies.  Think of all the items that are sold today that are currently manufactured, and then painted in a process that takes at least two steps.  Everything from the bodies of vehicles to clock faces require these steps, and if this printer is as effective as the company says, this could put an end to it.

Stratasys CEO, David Reis, said “I believe our new Objet500 Connex3 Color Multi-material 3D printer will transform the way our customers design, engineer and manufacture new products.” 

One of the early testers of this printer is the bike maker, Trek Bicycle in Waterloo, Wisconsin.  They are using the printer for testing and assessment of accessories such as bike chain stay guards and handlebar grips.  Mike Zeigle, manager of Trek’s prototype development group, said “Now we produce bicycle parts that look and feel like product parts.  We are particularly excited about 3D printing our models directly in color.”

The printer can even print transparent colors for even greater flexibility.  This is quite a leap forward for the 3D printing industry.  

Want to Listen to Music Louder? Print Off a New Speaker!

Researchers are using a new multi-material method of 3D printing that will allow them to print off working loudspeakers.  Indian-American Student, Apoorva Kiran, and a team at Cornell University in New York have already printed off a working loudspeaker.  The plastic, magnets and conductive parts are all printed seamlessly together, so it is ready to use almost right off the printer.

This is a great example of how things that currently require multiple parts to be assembled together will soon be able to be printed off as one solid piece.  This will not only cut the amount of time and money it takes to create these products, but it will also make them much more durable.  We won’t have to worry about a screw coming loose or adhesive coming apart.  The items we buy will be one seamless piece, which is, of course, much stronger.

Kiran said, “Everything is 3D-printed.  A loudspeaker is a relatively simple object.  It consists of plastic for the housing, a conductive coil and a magnet.  The challenge is coming up with a design and the exact materials that can be co-fabricated into a functional shape.”

For this printer, Kiran used silver ink for the conductor, and for the magnet a blend of strontium ferrite was used.   Of course, the plastic was the easiest part of the speaker.

This is quite an accomplishment, and really shows how important it is that 3D printers are starting to be able to print with multiple materials.  It is, according to the release, like going from an only black and white printer to a full color printer.  It opens a lot of doors that were previously shut, and we are really only scratching the surface of what will be able to be done with this technology. 

The bottom line here is, if you blow out a speaker in the future, you won’t have to run to the store or even visit Amazon.  You can just load in the schematics to your computer and print off the speaker of your dreams before you go back to jamming to Justin Bieber!

Major 3D Printing Patent Expired – Opening Industry for Major Advancements

US Patent 5597589, “Apparatus for producing parts by selective sintering” has officially expired.  This is one of the most important patents in the 3D printing world.  It allowed 3D printer companies to charge significantly more for the fine nylon powder that is often used in these machines.  This high cost has prevented many people (and businesses) from getting involved with 3D printing with any significant scale.

 

There are still some other similar patents out there, so it won’t be a simple matter of a company using this material tomorrow, however, this is a major hurdle that has now been passed.  Companies with large pocketbooks will likely start pushing for this material, and going to court to get past the other patents.  Once those patents either expire, or are ruled in court to not be a reason that other companies can’t use the nylon powder, we will really begin to see the price of 3D printing drop.

As with all new technologies, these patents are a dual edged sward.  The patents allow the most innovative companies to profit from their major advancements.  Since they don’t have competition, they can charge higher prices, which slows down the innovations made by the technology using that patent.  In the long run, however, it seems clear that this system works out well for everyone.

Many experts in the 3D printing field believe that this one patent expiring will start the ball rolling for the manufacturing and selling of many new SLS type 3D printers.  As more of them are made, the price will drop significantly, likely to the point where it is practical for the average Joe to have one in their house (if they are interested).  Innovative high schools and even middle schools will start purchasing them and helping students learn about these great tools, which will really open the door to advancement in every field over the next decade.  

The expiration of this patent may just be the thing that drives the biggest revolution within the 3D printing world, so keep an eye out over the next year for some amazing new capabilities and discoveries from 3D printing.