Episode #81 | From J&J to the Future: Sam Onukuri's 30-Year Adventure in 3D Printed Medical Devices
04/19/25 • 80 min
Sam Onukuri takes us through his remarkable 30-year journey at Johnson & Johnson, where he transformed the landscape of medical devices through pioneering work in 3D printing technology. As a material scientist who led the development of J&J's Center of Excellence for additive manufacturing, Sam offers rare insights into how a global healthcare giant approached innovation and personalized medicine.
The conversation reveals the fascinating evolution of medical 3D printing from basic prototyping to FDA-approved implants. Sam shares the story behind breakthrough products, such as the TrueMatch graft cage – a PCL-based, bioabsorbable scaffold for bone reconstruction that has dramatically improved patient outcomes. His candid assessment of where personalization succeeds (craniomaxillofacial implants) and where it falls short (knee replacements) provides a nuanced perspective rarely found in technology discussions.
We examine the unexpected challenges that have shaped the industry, including the complex regulatory landscape, the emergence of surgical robots, and the economic realities that have tempered some early expectations. Sam's firsthand experience with point-of-care printing initiatives and customized surgical instruments provides valuable lessons about striking a balance between innovation and practicality in healthcare settings.
Looking toward the future, Sam identifies promising frontiers, including bioprinting, advancements in materials science, and the integration of AI with 3D printing technologies. For students and professionals considering careers in this field, he emphasizes the importance of strong engineering fundamentals and experiencing both startup and corporate environments to develop a comprehensive skill set.
Whether you're a healthcare professional, engineer, investor, or simply curious about how medical innovation occurs, this conversation offers an authentic glimpse into the triumphs, setbacks, and unrealized dreams that continue to shape the future of personalized medicine and additive manufacturing.
Subscribe to our premium version and support the show.
Follow us:
Twitter
Instagram
Linkedin
3DHEALS Website
Facebook
Facebook Group
Youtube channel
About Pitch3D
Sam Onukuri takes us through his remarkable 30-year journey at Johnson & Johnson, where he transformed the landscape of medical devices through pioneering work in 3D printing technology. As a material scientist who led the development of J&J's Center of Excellence for additive manufacturing, Sam offers rare insights into how a global healthcare giant approached innovation and personalized medicine.
The conversation reveals the fascinating evolution of medical 3D printing from basic prototyping to FDA-approved implants. Sam shares the story behind breakthrough products, such as the TrueMatch graft cage – a PCL-based, bioabsorbable scaffold for bone reconstruction that has dramatically improved patient outcomes. His candid assessment of where personalization succeeds (craniomaxillofacial implants) and where it falls short (knee replacements) provides a nuanced perspective rarely found in technology discussions.
We examine the unexpected challenges that have shaped the industry, including the complex regulatory landscape, the emergence of surgical robots, and the economic realities that have tempered some early expectations. Sam's firsthand experience with point-of-care printing initiatives and customized surgical instruments provides valuable lessons about striking a balance between innovation and practicality in healthcare settings.
Looking toward the future, Sam identifies promising frontiers, including bioprinting, advancements in materials science, and the integration of AI with 3D printing technologies. For students and professionals considering careers in this field, he emphasizes the importance of strong engineering fundamentals and experiencing both startup and corporate environments to develop a comprehensive skill set.
Whether you're a healthcare professional, engineer, investor, or simply curious about how medical innovation occurs, this conversation offers an authentic glimpse into the triumphs, setbacks, and unrealized dreams that continue to shape the future of personalized medicine and additive manufacturing.
Subscribe to our premium version and support the show.
Follow us:
Twitter
Instagram
Linkedin
3DHEALS Website
Facebook
Facebook Group
Youtube channel
About Pitch3D
Previous Episode
Episode #80 | Live from San Francisco: Innovation in 3D Printing & Bioprinting
3DHEALS kicked off its first in-person/hybrid event in 2025 in San Francisco, welcoming investors, entrepreneurs, and innovators in the space. The healthcare industry is transforming, driven by 3D printing and bioprinting technologies redefining patient care. This exclusive in-person hybrid event offered an opportunity to explore the latest advancements in custom prosthetics, implants, bioprinted tissues, and scaffolds. The remarkable convergence of 3D printing and healthcare transforms medicine through customized solutions that weren't possible a decade ago. This episode brings together five leaders in the healthcare field who are harnessing additive manufacturing to solve real clinical problems and improve patient outcomes.
Summary:
- 3D-printed spinal implants have evolved from simple titanium cages to sophisticated expandable devices that restore alignment and relieve nerve compression
- Patient-specific radiation shields protect healthy tissue during cancer treatment, reducing devastating side effects like oral mucositis
- Bioprinted organoids are creating human-derived testing platforms for drug discovery
- 3D-printed trabecular metal structures are providing better bone integration for joint replacements
- AR/VR integration with 3D printing is a robust tool for surgical planning, training, and patient education..
- Evidence-based innovation remains critical, focusing on validated clinical problems rather than technology for technology's sake.
- The shift toward ambulatory surgical centers drives demand for minimally invasive solutions that 3D printing can uniquely deliver.
- Investment in medical 3D printing continues as clinical applications expand.
The experts emphasize that successful innovation must be evidence-based, addressing validated clinical problems rather than pursuing complexity for its own sake. The speakers agreed, "Just because it's complex doesn't mean it's better." This wisdom encapsulates the mindful approach needed as we continue exploring the vast potential of 3D printing in healthcare.
SUBSCRIBE to join us at future 3DHEALS conferences to connect with innovators and investors in the rapidly evolving field of 3D printing for healthcare applications.
Watch this event recording on demand.
Check out our blog for an in-depth analysis of the event!
Youtube Event Highlight Playlist.
Subscribe to our premium version and support the show.
Follow us:
Twitter
Instagram
Linkedin
3DHEALS Website
Facebook
Facebook Group
Youtube channel
About Pitch3D
Next Episode
Episode #82 | Advancing Microfluidic Technology Through 3D Printing (Virtual Event Recording)
Peering into the microscopic world of fluid channels just got a revolutionary upgrade. At this 3DHEALS event, we explore the transformative impact of 3D printing on microfluidic device development with industry experts and researchers at the cutting edge of this technology convergence. Our speakers share how specialized 3D printing systems are overcoming traditional fabrication limitations, enabling rapid prototyping and the creation of revolutionary new designs.
Summary:
- Hamdeep Patel from CatWorks3D discusses a specialized 3D printing system optimized for microfluidics with unbeatable feature resolution.
- CatWorks3D’s CytoClear material achieves 90% cell viability with optical transparency for direct microscopic analysis.s
- Paul Marshall from RapidFluidics provides rapid microfluidic prototyping services for researchers and companies worldwide.
- Professor Christopher Moraes from McGill University utilizes 3D-printed parts combined with biocompatible materials for advanced organoid culture applications.
- Jeff Schultz from Phase AM is developing technology to directly 3D print PDMS (Silgard 184) without modifications.
- Key adoption factors include leveraging 3D printing's unique capabilities rather than replicating 2D designs.
- The integration of world-to-chip interfaces, such as Luer locks, significantly improves device reliability.
- Creating truly 3D structures with complex internal geometries represents the future of microfluidics.
The consensus is clear: successful adoption requires leveraging 3D printing's unique capabilities rather than simply replicating 2D designs. As these technologies mature, we are witnessing the emergence of truly three-dimensional microfluidic systems with integrated functionality that promises to revolutionize diagnostics, drug development, and biological research.
SUBSCRIBE to join us at future 3DHEALS conferences to connect with innovators and investors in the rapidly evolving field of 3D printing for healthcare applications.
Watch this event recording on demand.
YouTube Event Highlight Playlist.
Podcast engineer: Faith Fernandes
Subscribe to our premium version and support the show.
Follow us:
Twitter
Instagram
Linkedin
3DHEALS Website
Facebook
Facebook Group
Youtube channel
About Pitch3D
The Lattice (Official 3DHEALS Podcast) - Episode #81 | From J&J to the Future: Sam Onukuri's 30-Year Adventure in 3D Printed Medical Devices
Transcript
In this episode , I had the pleasure to interview Sam Onokori , a pioneering force in the world of 3D printed medical devices with over 30 years of experience in R&D and commercialization . A trained material scientist , Sam has led transformative work during his 30-year tenure at Johnson Johnson , where he spearheaded 3D printing integration across medical , consumer and pharma secto
If you like this episode you’ll love
Episode Comments
Generate a badge
Get a badge for your website that links back to this episode
<a href="https://goodpods.com/podcasts/the-lattice-official-3dheals-podcast-240699/episode-81-from-j-and-j-to-the-future-sam-onukuris-30-year-adventure-i-89721882"> <img src="https://storage.googleapis.com/goodpods-images-bucket/badges/generic-badge-1.svg" alt="listen to episode #81 | from j&j to the future: sam onukuri's 30-year adventure in 3d printed medical devices on goodpods" style="width: 225px" /> </a>
Copy