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Augment Bionics was founded with the aim to produce highly functional and affordable 3D printed bionic prosthetics. To realise the full potential of our company, I set clear goals and aggressive deadlines that successfully transformed what was essentially a university project into a registered, five-person, company that had direction. Within a year of inception, we raised over £15,000 from entrepreneurial competitions which we used to fund our R&D.
As the CTO, my core responsibility was managing the engineering team and giving them direction to ensure that we were moving in one cohesive direction. Additionally, I worked on my own components and was the connecting link between the technical and commercial teams.
My main contribution was developing the method for designing and manufacturing the prosthetic socket, which can be see in the next section below. As the CTO, I was involved in the development of every single other component, which are showcased below.
Bionic Hand
Bionic Hand
Myoelectric prosthetics use electrical signals from your muscles to control a bionic limb - turning thought into movement.
The hidden spring loaded mechanism allows the finger to passively "relax" once the user wishes to open their hand.
Demonstration of the bionic hand with adjustable thumb positions holding various items.
Prosthetic Socket
Prosthetic Socket
The socket is the interface between the human limb and the prosthetic. If it is made incorrectly it can inflict pain and discomfort to the user. On the other hand, a dimensionally accurate and light socket will make the user feel like the prosthetic is a natural extension of themselves.
High quality sockets tend to come hand-in-hand with a significantly high price tag. This is an issue for all prosthetics users but even more so for children and teenagers. Their limbs constantly grow longitudinally and circumferentially which means that prosthetics must be frequently replaced to accommodate for this growth.
For my final-year dissertation I researched the application of digital manufacturing techniques in the production of prosthetic sockets. I found that through 3D scanning, 3D modelling and 3D printing, high levels of quality and comfort can be achieved at a low price point when compared to prosthetic sockets manufactured through traditional means.
Traditionally, socket manufacturing requires high levels of craftsmanship, wastes large volumes of non-reusable materials and is labour-intensive. These factors result in long lead times and high costs.
The aim of my final year's individual project was to replace traditional methods of socket production with digital manufacturing techniques. This allowed me to create a high quality, cost-effective socket in a relatively short period of time and test it with an experienced prosthetics user.
3D Scanning - The first step in the socket-production process is to measure the individual's residual limb. Traditionally, this is done using physical tools, plaster casting and other archaic measurement techniques. These methods can be lengthy, at times uncomfortable and introduce human error into the process.
My novel method uses a structured-light 3D scanner to capture the surface geometry of the individual's limb. It introduces several critical benefits such as contact-free measurement, higher dimensional accuracy and, most importantly, a significant reduction in human error. In addition, the process is extremely quick and does not require extensive training to master.
The very first step in the novel socket manufacturing process is already more comfortable, quick and accurate than the traditional counterpart. The next iteration of this technique would be the implementation of photogrammetry, where an accurate 3D model of the individual's limb could be generated from a simple smartphone video.
3D Modelling - Following a series of defined modelling steps, the 3D model of the socket is designed using the 3D scan of the residual limb as a base. Components such as the anchor at the bottom of the socket and holes for myoelectirc-sensors are added to integrate the socket with the rest of the prosthetic. The 3D modelling process could be automated on programmes such as Blender to reduce the cost and lead time of the socket even further.
3D Printing - The 3D model of the socket is printed on an FDM printer. The material used in the final socket was PETG. It can be cleaned using alcohol-based disinfectants and is skin-safe. The user trial showed that the 3D printed socket felt as comfortable and secure as a carbon fibre socket manufactured by a professional prosthetist.
The prototypes of the socket were printed in PLA as it is much cheaper and easier to print than PETG. Two PLA socket prototypes were made before the perfect tolerances were found for this particular individual. The total cost of the two PLA sockets and the final PETG socket was approximately £10. Compared to the £5000 carbon fibre socket which this particular individual was using, this is a huge reduction in cost an allows for cheap and rapid iteration of a vital medical device.
The images below are from the second run of the PLA socket prototype. A load was applied to the socket to measure the levels of comfort and security the individual experienced in common load conditions. The individual reported that the maximum load they could lift and the levels of comfort were comparable to what they experienced with their standard prosthetic.
3D Scan of patient's residual limb.
Patient testing the socket under load.
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