Victoria Hand: Providing 3D Printed Prosthetics to Amputees in the Developing World
At the University of Victoria, a team of engineers, designers, and volunteers is working hard to provide 3D printed prosthetics to amputees in the world's poorest regions. It's a challenging but very unique job. They are the Victoria Hand Project, and today we're going to tell you their story.
Adaptive Grasp
In the late 1990s, Dr. Nikolai Dechev was working on his doctoral project to create a breakthrough prosthetic technology, which he called Adaptive Grasp. Adaptive Grasp allowed fingers to curve around objects when the hand closed. At the time, the hands were designed to be welded onto CNC machines. This high-cost manufacturing method was an unwise choice. And it is precisely at this point that 3D printing began to make its mark. Seeing the potential of this technology, Dechev and his colleague Joshua Coutts modified the design and started the Victoria Hand Project.
Due to limited resources, restricted access to rural areas, lack of expertise, and high costs, prosthetics are often difficult to obtain in developing countries. 3D printing offers a solution to these problems, allowing the team to reduce costs and print and assemble locally in each country. With 3D printers and the right materials, clinics can print personalized medical devices or replacement parts, even in remote areas. For example, in Nepal, a team of engineers travels with their 3D printer to create medical devices and replacement parts for machines. This method is easier and cheaper than transporting specific parts and large boxes.
They needed a printer that could provide high-quality finished products with strong connections between each plastic layer. The Ultimaker 2 was ideal. Due to its high quality, the Ultimaker 2 is an easy-to-use 3D printer with available resources for maintenance and troubleshooting.
How Ultimaker 2 Works
First, a prosthetist assesses the amputee. A model of the residual limb is made, and then the prosthetist creates an interface between the device and the body. The Victoria Hand Project team captures the prosthetist's skills through custom 3D scanning of plaster molds. This scan is then used to create a custom 3D printed socket for the amputee.
The hand and wrist components take about 48 hours to print, then are assembled and attached to the custom socket. The final step is to paint the prosthesis to match the natural skin tone. This aesthetic touch helps amputees feel more confident.
Training is provided to all 3D printing lab staff, plus prosthetists and clinicians.
Challenges of 3D Printing
In 2014, the Victoria Hand Project team researched different 3D printers and found that the Ultimaker 2 was best suited for the task. Initially, they also ordered an SLA 3D printer, but it resulted in many failed prints and did not provide the required clean environment. The parts were also too fragile for practical use. Therefore, it proved that Ultimakers are easier to use, which means clinicians and prosthetists can quickly learn how to operate them.
Some problems still occurred along the way, but Ultimaker's guides and forums helped them learn how to use and maintain the 3D printers. Print quality improved, and the manufacturing process sped up. Over the years, the team gained valuable experience using 3D printers and was able to provide technical services to other clinics. They personally trained medical workers to ensure they knew how to assemble and fit prostheses. This encouraged closer relationships among clinic staff.
The team also learned that 3D printing in clinics differs from printing in the University of Victoria lab. For example, in Nepal, there are daily power outages. Without a UPS, sockets cannot be printed. In other clinics, it is hot and humid, which can alter the properties of materials. In Kathmandu, the air is dusty, which means the heated bed needs to be cleaned more frequently, making the process more expensive. Additionally, shipping and import fees make replacement parts expensive, even for tiny nozzles.
Material Selection
Sometimes, knowing the best print settings is challenging. Using the Ultimaker 2+ printer, the Victoria Hand team tested print speeds and layer thickness to find the optimal settings, and tested different materials such as PLA, ABS, Nylon, and PET. Engineering student volunteers conducted tensile tests and failure analysis in each case. These tests allowed the Victoria Hand Project to improve their designs.
Students found black PLA to be the best. It is strong and requires less pre-processing time. Other materials are more difficult to print; for example, while ABS is also strong, it does not adhere firmly to the heated bed. This is problematic for inexperienced 3D printer users (such as clinic staff). PLA offers excellent quality and is easy to use - making it the ideal 3D printing material.
From Guatemala to Cambodia and Beyond
After receiving the Grand Challenges Canada award, the Victoria Hand Project collaborated with sports programs in Guatemala. Short-term and long-term trials were conducted, confirming the urgent need for high-quality prostheses without cost. Designer Joshua Coutts recalled his third visit, when he realized the local potential of 3D printers.
Before that, he focused on developing hand function. In the third trial, both function and ease of use, as well as aesthetics, improved, making a world of difference. It felt as if the hard work had finally paid off, and they were finally providing life-changing results.
Since then, the Victoria Hand Project has partnered with other clinical partners in Nepal, Haiti, Cambodia, and Ecuador. Clinics find amputees, print and assemble hands, and fit prostheses. The Victoria Hand Project team sets up equipment, trains local staff, and provides support and ongoing follow-up.
Sponsors and Supporters
This project would not have been possible without several generous donations. Grand Challenges Canada funded the initial development and trials and expanded their help to establish more clinics. Ultimaker donated four Ultimaker 2+ 3D printers, a critical component of the operation. The Enable Community Foundation funded the clinic in Haiti, and other donations were achieved through crowdfunding and fundraising.
Although the Victoria Hand Project has collaborated with E-nable, the design teams are now separate. E-nable operates an open-source model that allows people to download designs and then print them anywhere with a 3D printer. The Victoria Hand Project only provides STL files and Gcode files to collaborators. This ensures the excellent quality of 3D printed prosthetics and maintains a good reputation.
New Equipment
In addition to 3D printed hands, the team has begun developing other medical devices using 3D printing; for example, adjustable foot orthoses, ankle braces, and finger splints. They use the same hardware and materials, so new designs sent to clinics via email can start printing immediately.
Since PLA is a thermoplastic, heat guns or hot water are used to thermoform parts. When the material softens, it can be formed around the limb; then, when it cools, it becomes rigid and provides support.
Future
The Victoria Hand Project aims to further improve the system for amputees, raise funds, and establish more partnerships worldwide. Raising awareness and securing financial support are key factors in achieving this goal. Watch this space to learn more about this amazing project!
Original text:https://ultimaker.com/en/stories/23486-victoria-hand-providing-3d-printed-prosthetics-to-amputees-in-the-developing-world
[3D Printing News] Victoria Hand 3D Printed Prosthesis