Release date: 2016-05-17

  German athlete Denise Schindler is working with Autodesk to become the first athlete to use a full 3D printed prosthetic for a bicycle race at the 2016 Paralympic Games in Rio de Janeiro, Brazil. "This will be the world's first 3D printed prosthesis at the Paralympics," said Paul Sohi, a product designer at Autodesk. “We are at a stage of technological maturity and will be leading the transition in this industry.”

Schindler was the silver medalist at the 2012 London Paralympic Games, and her right leg was amputated after an accident in childhood. In order to ride a bicycle, she used a specially designed prosthetic leg. "I am amputated below my knees," Schindler explained. "I have a special bicycling leg that fits the pedal."

Schindler usually uses a hand-made carbon fiber prosthesis, but last year she worked with orthopaedic technician Thomas Wellmer and Autodesk Software to create a 3D printed polycarbonate prosthesis.

Sports prostheses are highly customized and sophisticated equipment that needs to be redesigned and modified on a regular basis to accommodate the athlete's slightly changing body over time. This is currently a highly artificial, time consuming and expensive process, but Schindler and Sohi believe that by using 3D scanning and printing technology, they can greatly accelerate their progress.

“The stuff is still handmade, and it will last a long time,” Sohi explained. “But gypsum castings can be changed to 3D scanning, the design of the socket can be changed to digital engraving, and the carbon fiber molding can be changed to 3D printing.”

Schindler added: "The biggest benefit of doing it digitally is that the process is very fast. With 3D models, we can see better changes and react faster." Sohi has been using Autodesk's Fusion 360 software, through Schindler's residual limbs. 3D scanning to design prostheses. “Fusion360 is a full-featured software package, so it can do modeling, animation and simulation work,” Sohi explained. “We can make changes quickly and see how factors such as material stress will affect the prosthesis.”


Schindler and Sohi have designed and tested a series of iterative prostheses that will be divided into two parts using polycarbonate for 3D printing.

Currently, Schindler is training with the latest version of prosthetics, while Sohi continues to improve the design to allow Schindler to use the final version at the Paralympics.

"With the latest version, we can definitely achieve a goal because I can really ride it," Schindler said. “I even trained outside and on the track, so I was really surprised that we have made great progress.”

Schindler's short-term goal is to adapt to the prosthesis and win the gold medal at the Rio de Janeiro Paralympics in the second half of this year, when she will compete on several different roads and tracks.

However, both Schindler and Sohi believe that by creating a sports prosthesis, the project can have far-reaching effects, making customized sports prostheses more affordable and convenient, and before that it was usually designed for elite athletes. “Because everything is digital, you can make the manufacturing method popular and build prosthetics anywhere in the world,” Sohi said. “This is the future of artificial prosthetics.”

“The new technology is great for me, but my biggest goal is to really open up the world of sports for every amputated person,” explains Schindler. “Even if you are amputated, you can remain active, confident, and enjoy life. It doesn't give up, it makes a lot of sense."

Source: 3D Sandworm

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