Why AM and Orthotics & Prosthetics are the Perfect Fit

Additive Snack · 14 Jul 2026 · 1h 14m · Episode 36

What this episode covers

Brent Wright, VP at EastPoint Prosthetics and co-founder of Life Enabled, explains how additive manufacturing is transforming orthotics and prosthetics (O&P) by replacing hazardous, non-digital traditional workflows with scalable, data-driven digital processes. He details the shift from plaster casting and carbon fiber layups to pressure casting, 3D scanning, and SLS printing with materials like PK5000 to create flexible sockets that heal wounds and improve comfort. Wright discusses the challenges of scaling care in developing regions like Guatemala through local manufacturing and modular kits, while noting that reimbursement barriers in the US limit the adoption of advanced sensors and actuators.

Other shows on the same ground, closest first.

  • The Next Byte Podcast · 23m

    42. World's Most Advanced Prosthetics

    Hosts Daniel and Forbode discuss two engineering breakthroughs: an MIT and BASF collaboration using machine learning to accelerate material discovery, and a partnership between Life Enabled and Entopology using generative design and 3D printing to create affordable, custom prosthetics for developing countries. They detail how AI optimizes chemical formulations and how digital workflows replace labor-intensive casting, significantly reducing cost and time for amputees in places like Guatemala. The episode highlights the shift from manual, expert-dependent processes to scalable, remote, and data-driven manufacturing.

  • The Next Byte Podcast · 23m

    21. AI Rescues Firefighters, NASA Prints Spacecraft Parts, Plug & Play Prosthetics

    Hosts Daniel and Forbode discuss three engineering stories: an AI model by NIST that predicts flashover in fires using sensor data and simulations; NASA’s use of ultrasonic additive manufacturing (UAM) via subcontractor Fibrosnic to create complex, dissimilar-metal heat exchangers; and Levitate, a company founded by an amputee in partnership with the Technical University of Denmark, which offers affordable, plug-and-play athletic prosthetics using proprietary composite materials.

  • Being an Engineer · 45m

    Ray Fikes | Prosthetics and Hacking 3D Printers

    Ray Fikes, founder of Fikes Brace & Limb, explains how he has used 3D printing, laser scanning, and CNC machining to solve complex prosthetic challenges over 40 years. He details his proprietary 'vase mode' 3D printing techniques using PETG and Combscan iPhone scanning to create diagnostic sockets, while relying on carbon fiber layup for definitive devices. Fikes discusses the critical importance of alignment, volume fluctuation management, and the 'blanching' technique to prevent tissue damage, alongside his development of custom swim fins and rapid wrap systems.

  • Being an Engineer · 52m

    Scott Summit | Industrial Design, 3D Printing, & Life-Changing Products

    Scott Summit, a senior industrial designer and former design director at 3D Systems, discusses his career designing life-changing products, including 3D-printed orthotics and prosthetics. He details the technical challenges of using CAD tools like Pro/ENGINEER for organic shapes, the strategic shift to Autodesk Fusion 360, and the importance of industrial design in improving patient compliance for medical devices. Summit also shares insights on his work with Will.i.am on the Cube printer, the development of 3D printing technology for space via Made In Space, and his vision for bespoke, algorithmically generated consumer goods like custom shoes.

  • The Manufacturing Executive · 26m

    Building an On-Demand Supply Chain in America's Urban Core w/ Elias Stahl

    Elias Stahl, CEO and co-founder of HiloS, explains how his company is using advanced additive manufacturing to create footwear on demand, aiming to eliminate waste and bring production back to urban centers. Stahl details the inefficiencies of the traditional footwear supply chain, noting that while it takes 12-18 months to bring a shoe to market, HiloS reduces this to 90 days by simplifying parts and removing tooling. He discusses the second wave of 3D printing, highlighting improvements in hardware, materials, and software that now allow for scalable, industrial-grade production. The conversation covers the vision of integrating clean manufacturing into city cores to revitalize urban economies and the challenges brands face in shifting from low-cost, high-volume models to on-demand, higher-cost-per-unit models.

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