Dynamic 3D Printed Knee Orthoses with Dave Johnson
07/26/24 • 50 min
Maybe the solution to your knee pain is a high-tech 3D-printed brace inspired by an injury from the football field. Today, we’re talking to Dave Johnson, the CEO and founder of the startup Icarus Medical, about his unusual path from a childhood on a dairy farm to inventing innovative knee braces. Dave describes how his life journey and a successful career in chemical engineering for the Department of Defense provided the inspiration for developing a high-performance, metal-free knee brace for fighting patellofemoral osteoarthritis.
And 3D printing how? Dave provides an ingenious step-by-step, from the first heavy, bulky prototypes to their eventual lightweight, contour-fit, form-fitting incarnation. His descriptions of the iterative development, including his incorporation of an elastomeric band to improve fit and tolerance, as well as the employment of a biomedical engineering intern, are both fascinating and informative. Moreover, he recounts how his team realised that the heaviest components came from the support material used in the printing process and, thus, shifted to Multi-Jet Fusion technology, which is cheaper and can be produced in much shorter runs. By the time we had finished, we wondered whether perhaps the biggest takeaway was that these state-of-the-art, individualised, contour-fit, 3D-printed, durable, adjustable, lightweight knee braces for leverage-control osteoarthritis became economically viable in greater number because of the strategic application of HP’s Multi-Jet Fusion technology.
But as much as it’s about the tech and engineering, it’s also about the people who are running the ship. In this episode, we spotlight the empathetic, patient-centric culture at Icarus Medical, where no two braces are ever the same, and every person is accommodated for, because – simply put – they can be. Dave takes us through the extensive process of getting a custom brace, from scanning to finishing to quality control to shipping, and into the nitty‐gritty of maintaining good relationships with outsourced contractors. And along the way, Dave shares some of his hard-won lessons on cost management, market research, and the power of staying true to your vision and having conviction in your product. If you’re at all interested in technology, medicine and innovation, you do not want to miss this episode.
This episode is brought to you by Advanced 3D.
Maybe the solution to your knee pain is a high-tech 3D-printed brace inspired by an injury from the football field. Today, we’re talking to Dave Johnson, the CEO and founder of the startup Icarus Medical, about his unusual path from a childhood on a dairy farm to inventing innovative knee braces. Dave describes how his life journey and a successful career in chemical engineering for the Department of Defense provided the inspiration for developing a high-performance, metal-free knee brace for fighting patellofemoral osteoarthritis.
And 3D printing how? Dave provides an ingenious step-by-step, from the first heavy, bulky prototypes to their eventual lightweight, contour-fit, form-fitting incarnation. His descriptions of the iterative development, including his incorporation of an elastomeric band to improve fit and tolerance, as well as the employment of a biomedical engineering intern, are both fascinating and informative. Moreover, he recounts how his team realised that the heaviest components came from the support material used in the printing process and, thus, shifted to Multi-Jet Fusion technology, which is cheaper and can be produced in much shorter runs. By the time we had finished, we wondered whether perhaps the biggest takeaway was that these state-of-the-art, individualised, contour-fit, 3D-printed, durable, adjustable, lightweight knee braces for leverage-control osteoarthritis became economically viable in greater number because of the strategic application of HP’s Multi-Jet Fusion technology.
But as much as it’s about the tech and engineering, it’s also about the people who are running the ship. In this episode, we spotlight the empathetic, patient-centric culture at Icarus Medical, where no two braces are ever the same, and every person is accommodated for, because – simply put – they can be. Dave takes us through the extensive process of getting a custom brace, from scanning to finishing to quality control to shipping, and into the nitty‐gritty of maintaining good relationships with outsourced contractors. And along the way, Dave shares some of his hard-won lessons on cost management, market research, and the power of staying true to your vision and having conviction in your product. If you’re at all interested in technology, medicine and innovation, you do not want to miss this episode.
This episode is brought to you by Advanced 3D.
Previous Episode
The Future is Now: 3D Printing in Prosthetics with Katie Richmond
What if the future of prosthetics could be completely transformed by a single machine? This episode of the Prosthetics and Orthotics Podcast kicks off Season 9 with an in-depth recap of the Rapid conference, highlighting the revolutionary Impossible Objects machine. Discover how continuous carbon fiber technology is set to change the landscape of 3D printing for prosthetics. We also shine a spotlight on an innovative elastomer from the Loctite Henkel Group, designed to mimic the comfort and durability of memory foam, opening up exciting new possibilities for patient care.
We then explore the intersection of technology and fashion with HP's MultiJet Fusion 580 printer, revolutionizing the eyewear industry. Learn how custom-fit, stylish glasses with wood grain finishes can be produced on-demand, reducing waste and meeting consumer demands more efficiently. Plus, we delve into the realm of metal 3D printing, discussing the accessibility and safety of newer, more affordable machines like the One Click Metal system and how they are democratizing advanced manufacturing.
Finally, we take you on Katie's journey through the evolving field of O&P. Hear about the shift towards 3D printing and CAD design, with practical tips for newcomers. We also examine the benefits and challenges of using lattice structures in orthotics and prosthetics, emphasizing the importance of design precision and material selection. Tune in to discover how small, in-house 3D printers are becoming indispensable tools for prototyping custom solutions, and the growing need for clinicians to embrace these technologies for better patient outcomes.
Next Episode
Have We Missed Something? with Tom Cutler
Have we missed something? In this episode we go back to the basics. Actually we go before the basics and that is surgery. Does the quality of surgery affect outcomes? What makes a good amputation? What makes a good outcome? Are prosthetists asked to do miracles? What is the role of the IT band in normal gait?
We cover this and more with Tom Cutler. If you listen to this episode and have not been challenged to think and consider what we have learned well....I did not do my job.
This episode is brought to you by Advanced 3D.
Resources:
Here's the video clip of femur vs IT band hip action: Link.
Here's the animation showing how large the horizontal force is at the hip vs at the ground: Link.
Here's the theory about the IT band being 30% of hip power: Link.
Here's the article about TF amputees missing 30% of hip power. Link.
This has amputees at up to 40% deficient. Link.
Here's Gottschalk's article about amputation surgery: Link. Page 19 shows the sharp edge, open bone marrow, and the text about moving the tensor fasciae latae.
Here's Gottschalk's article (Link) about TFL being the most important hip muscle in gait (page 184) and the gluteus medius being inactive during stance while TFL shows intense activity (pg 182).
Here's Pohl 2015 about a gluteus medius nerve block followed by... NOTHING! Link. There's no trendelenburg gait... no changes...
What about increased cardiovascular morbidity after amputation?
Here's an article about a 10 year old dying of fat embolism syndrome after TF amputation. Link.
Here's a spike in cardiovascular mortality in traumatic amputees (amazing data, very sound). Link.
What about the validity of the "adductor myodesis" technique? Link. According to this article surveying surgeons, "it is not possible to stitch the muscles to the bone due to the lack of fasciae structures." and a very telling statement "I have been a surgeon for 40 years and have learned by bitter experience. The information provided in the literature is miserable and I often
disagree with the arguments."
To all of the above, consider this: there's no skeletal support. End of discussion, right? Until we provide amputees with skeletal support, everything else is moot.
The Prosthetics and Orthotics Podcast - Dynamic 3D Printed Knee Orthoses with Dave Johnson
Transcript
Welcome to Season 9 of the Prosthetics and Orthotics Podcast . This is where we chat with experts in the field , patients who use these devices , physical therapists and the vendors who make it all happen . Our goal To share stories , tips and insights that ultimately help our patients get the best possible outcomes . Tune in and join the conversation . We are thrilled you are here
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-prosthetics-and-orthotics-podcast-226838/dynamic-3d-printed-knee-orthoses-with-dave-johnson-64674237"> <img src="https://storage.googleapis.com/goodpods-images-bucket/badges/generic-badge-1.svg" alt="listen to dynamic 3d printed knee orthoses with dave johnson on goodpods" style="width: 225px" /> </a>
Copy