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We catch up with Niles from Leonard Industries, our first-ever returning guest, as he reveals game-changing innovations in prosthetic and orthotic fabrication technology. This episode explores how new manufacturing tools are making fabrication faster, safer, and more consistent while helping address the industry's technical workforce challenges.

• Leonard Industries has expanded by acquiring a machine shop with enhanced capabilities
• Their revolutionary Wave Oven cuts heating time from 20 to 7 minutes using targeted infrared technology
• The oven creates consistent results with wider work windows, eliminating the need to flip materials
• Safety innovations include emergency stops, magnetic starters, and controlled heating
• Multiple oven models accommodate different fabrication needs, from standard to large KFO applications
• The "toast test" demonstrates heating consistency by showing how evenly bread slices brown
• Leonard Industries will showcase their technology at the upcoming AOPA conference
• The company has helped establish safer educational environments at O&P schools
• Niles emphasizes making fabrication more accessible to new technicians through consistency and automation
• Their aluminum construction ovens use less energy while providing more precise heating control

Visit the Leonard Industries booth at AOPA to see live demonstrations of their new fabrication technology, including the Wave Oven, dust collection systems, and fume extractors.

Special thanks to Advanced 3D for sponsoring this episode.

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We preview the upcoming AOPA National Assembly in Orlando, discussing what makes this prosthetics and orthotics trade show valuable for professionals across the industry.

• AOPA (American Orthotic and Prosthetic Association) National Assembly happening September 3-6 in Orlando, Florida
• 165+ exhibitors representing various aspects of the O&P industry 
• Educational tracks covering clinical, technical, business, and pedorthic topics
• Up to 34 continuing education credits available in person, with 100+ hours of online content afterward
• Hands-on technical laboratory for fabrication techniques and safety equipment demonstrations
• Digital Showcase featuring case studies and workflow solutions from different vendors
• Administrative Law Judge mock trial simulating insurance appeal processes
• Strong 3D printing presence with 33+ companies showcasing additive manufacturing solutions
• Notable exhibitors including long-established companies and first-time participants
• Importance of consistency at trade shows for building relationships and trust in the industry
• Networking opportunities that facilitate business connections and partnerships

Join us at the Prosthetics and Orthotics Podcast booth where we'll be broadcasting live throughout the event!

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Brad Matear, who oversees central fabrication for Shriners Children's hospitals, shares insights on the technical side of O&P, highlighting the critical shortage of trained technicians and pathways for advancing the profession.

• Shriners Children's central fabrication serves approximately 19 facilities nationwide, dealing with complex pediatric cases that require exceptional technical skill
• The field faces a serious technical talent shortage with 15-16 clinical schools but only 4 technical schools producing graduates
• Technician compensation and recognition are crucial factors in retention, with approximately 30% attrition rate compared to clinicians
• Digital fabrication including CAD/CAM and 3D printing represents the future for technicians, requiring new educational approaches
• The Assistant Credential offers a promising middle path between technical and clinical roles, similar to the PT/PTA model
• Technical education must evolve to include both traditional hand skills and advanced digital techniques
• AOPA 2025 in Orlando will feature hands-on technical education including custom fabrication and alignment techniques
• Proper disposal and recycling of materials remains a challenge, particularly for foam products used in fabrication

Please recycle your plastics as best you can and if you're an engineer with ideas for recycling carving foam, the industry needs your solutions to reduce landfill waste.

Special thanks to Advanced 3D for sponsoring this episode.

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Rich Dubin, CEO of LER Expo, shares his journey creating digital educational platforms that foster cross-disciplinary learning for healthcare professionals in the lower extremity market. We discuss how bringing together specialists from different fields—from podiatry to orthotics and prosthetics—leads to better patient outcomes and more innovative approaches to care.

• Founded LER Expo in 2019, perfectly timed before COVID shut down in-person educational events
• Created an engaging digital conference platform that recreates the in-person experience with lobbies, exhibit halls, and networking spaces
• Uses innovative approaches like tournament-style presentations to keep audience engagement high
• Emphasizes the importance of cross-disciplinary education across healthcare specialties
• Discusses concerns about the rising cost of O&P education with master's programs approaching $200,000 in total costs
• Highlights the critical value of mentorship and hands-on experience versus academic credentials alone
• Shares practical advice for clinicians wanting to present at virtual conferences
• Believes collaborative care across disciplines leads to better outcomes for patients
• Encourages professionals to look beyond their specialty silos to find new connections and innovations

Special thanks to Advanced 3D for sponsoring this episode.

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We explore the exciting intersection of engineering, biomechanics, and 3D printing in prosthetics with our guest Ashton Stoop, who shares his journey from mechanical engineering student to designing 3D-printed prosthetic limbs in Mexico.

• Ashton's background in mechanical engineering and his path to O&P through biomechanics research
• The importance of both functionality and emotional integration in prosthetic design
• How custom prosthetic covers serve as tools for patient acceptance and identity
• Using Rhino and Grasshopper software to create automated workflows for socket design
• The balance between maintaining clinical control and leveraging AI automation
• The potential for 3D printing to democratize the prosthetics industry
• How small clinics can compete with larger corporations through innovative technology
• The critical importance of clinical evaluation and fitting despite technological advances
• Challenges in biomechanical understanding of complex structures like feet and ankles
• Community initiatives like the Digital Limb Collective that share knowledge and best practices

The field of prosthetics needs professionals from all backgrounds – you don't have to be a clinician to make a difference in people's lives. If you have design skills and a passion to help others, there is room for you to contribute to this meaningful work.

Special Thanks to Advanced 3D for sponsoring this episode.

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Dhruv Agrawal, founder of Aether Biomedical, shares how a birthday gift 3D printer led him from medical school to developing the Zeus hand, the strongest bionic prosthetic hand on the market with revolutionary cloud-based tracking capabilities.

• Journey from medical student to prosthetics innovator began with a 3D printer birthday gift
• Uses additive manufacturing not just for prototyping but for actual production components
• Zeus hand features industry-leading grip strength and 30-minute repair capability
• Cloud-based platform tracks usage data, showing super users complete 700-800 grip cycles daily
• Data collected helps optimize device settings and provides evidence for insurance authorization
• Most users rely on 4-6 standard grips plus 2-3 customized grips for specific activities
• Currently working on multiple versions of the Zeus hand at different price points
• Long-term vision is to become "the operating system for assistive devices" across prosthetics, orthotics, and exoskeletons
• Company of 60 people with half dedicated to research and development
• Future developments include VR training tools for phantom limb pain management

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Jochen Weigel from Stuttgart, Germany joins us to discuss his innovative contributions to prosthetics, including post-processing for Niagara feet and the development of the AirFit casting system.

• Jochen's journey from clinical specialist to R&D manager to starting his own business 13 years ago
• The AirFit system uses air pressure instead of water to create comfortable prosthetic sockets
• Air pressure uniquely compresses only soft tissue while preserving bony structures
• Testing in Kenya combined the AirFit system with low-temperature thermoplastic sockets for immediate fitting
• The Niagara foot provides exceptional durability compared to SACH feet commonly used in developing regions
• Made with special DuPont material (Hydrel) through a complex molding process few can replicate
• The foot works across weight ranges from 70-190 pounds when properly tuned
• High initial cost compared to $20 Chinese alternatives creates adoption challenges despite long-term savings
• Ways to help include volunteering with NGOs, making targeted donations, or collaborating with small companies

If you have ideas for prosthetic products that could help in developing regions, reach out to smaller companies who are more likely to be interested in humanitarian solutions.

Special thanks to Advanced 3D for sponsoring this episode.

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The mobile prosthetic clinic model is gaining traction as Hanger acquires Colorado-based Agile Orthopedics, potentially changing how prosthetic care is delivered nationwide. Raise3D's new RMS-220 SLS printer enters the market with open material capabilities, challenging the economics of small-scale prosthetic production.

• Mobile clinics solve transportation challenges for patients with mobility limitations
• Bringing care directly to patients is especially valuable in rural areas with weather challenges
• Centralized fabrication pairs perfectly with mobile clinical services
• Hanger could dramatically expand market reach by adding mobile clinics to existing locations
• Open-material 3D printers may help control costs when material prices increase but reimbursement doesn't
• Entry-level SLS systems face challenges with powder handling and economic viability
• Lattice structures should be used thoughtfully based on function, not just aesthetics
• Using others' designs without permission demonstrates disrespect for intellectual property

Join us next time as we continue exploring innovations in prosthetics and orthotics. Remember to subscribe to the podcast and share with colleagues who might benefit from these discussions.

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David Pierick, a retired Applications Engineer, shares the journey of bringing powder bed fusion technology to prosthetics and orthotics, revolutionizing patient comfort and outcomes through advanced materials.

• The initial challenge: proving 3D printed prosthetic components were as good or better than traditional methods
• Testing showed printed sockets were remarkably strong—in one test bending the aluminum testing rod before deforming the socket
• Patient feedback consistently reported greater comfort with PA-12 sockets, especially when paired with flexible interliners
• PA-11 offers superior fatigue properties and better strength-to-stiffness ratio than PA-12, though at higher cost
• PK5000 combines nylon stiffness with TPU softness, enabling thinner socket designs with excellent impact resistance
• Proper design principles are critical: avoid sharp edges, ensure proper radii on all features, and properly transition corrugations
• Future innovation requires thinking beyond traditional manufacturing constraints and adopting true 3D design approaches
• Collaborative teams of polymer experts, design specialists, and clinicians are essential for solving complex challenges
• New applications could include integrated functionality with shock absorption zones and varying flexibility in a single component

Special thanks to Advanced 3D for sponsoring this episode.

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Dr. Nate Crider joins us to discuss his approach to prosthetic care through telemedicine, where he bridges the gap between prosthetists, patients, and insurance requirements. As a PM&R specialist, he has expanded to 14 states in just three years, improving outcomes by bringing medical expertise directly to prosthetic clinics.

• Telemedicine solves mobility challenges for amputees while improving communication between medical and prosthetic providers
• Insurance documentation requires specific medical necessity language that many primary care providers don't understand
• Collaborative appointments with patients and prosthetists ensure accurate assessment of functional needs and appropriate technology selection
• Technology advancements including osseointegration, pattern recognition for upper extremities, and K2 microprocessor knees are changing patient options
• Proper socket fit, liner replacement, and supply management significantly impact patient comfort and functional outcomes
• Interdisciplinary approaches with surgeons, PM&R specialists, and prosthetists lead to better amputee care from surgery through rehabilitation
• Small and large prosthetic practices benefit from specialized medical documentation support that reduces denial risks

For more information about Dr. Crider’s telemedicine services, connect with him on LinkedIn or contact Madrina company, which operates in 46 states.

A special thanks to Advanced 3D for sponsoring this episode.

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