Challenge

Quorum Prosthetics, an innovative healthcare provider, utilizes digital technologies, including 3D printing, to produce custom-fitted Quatro™* prosthetic sockets for their patients. For production of their custom prototypes, including a soft inner prosthetic socket able to withstand constant use, Quorum approached Avid Product Development, part of Lubrizol’s 3D Printing Solutions business.

Solution

For the flexible inner sockets, Avid recommended using ESTANE 3DP TPU M95A for HP Multi Jet Fusion* (MJF) 3D printing technology. This polymer provided the flexibility and durability necessary for prosthetic inner sockets as well as an adequate level of softness for enhanced patient comfort. An inner socket can be worn an estimated two million steps a year and can last multiple years without wearing out, a real advancement for the prosthetic industry. With an estimated 3-year use cycle and 2 million steps a year, Quorum has not witnessed a flexible inner socket wear out yet.

“Versatile for prosthetic applications, our custom engineered 3D printed sockets last longer than traditionally manufactured sockets,” said Joe Johnson, Quorum’s CEO and Certified Prosthetist.

ESTANE TPU M95A was also a great compliment to the outer hard socket printed out of PA12. With 3D scanning and printing, both components can easily be redesigned and manufactured to accommodate volume fluctuations in residual limbs. These digital technologies eliminate the need for refitting and using plaster casts to mold a replica of the patient, a process that is often messy, time-consuming, and requires the patient to be on site.

Result

3D scanning and additive manufacturing minimizes the time and resource requirements to custom-fit prosthetics. 3D printing provides the “design freedom to change material durometers and rapid iteration,” stated Johnson. Amputee patients can benefit from customized, comfortable prosthetics with a flexible, long-lasting, and soft inner socket produced in ESTANE 3D M95A TPU.

The use of innovative materials, like ESTANE M95A TPU, and production-grade 3D printing, has allowed Quorum Prosthetics to fabricate a custom prosthetic that is flexible, resilient, and comfortable. With guidance from Avid, Quorum Prosthetics scaled up production of their 3D printed Quatro prosthetic sockets by investing in a HP Multi Jet Fusion** (MJF) 3D printer, manufacturing exclusively in ESTANE 3D M95A TPU and PA12.

Quorum Prosthetics’ web site: https://opquorum.com

Photo courtesy of Quorum Prosthetics

*Quattro trademark is property of Quorum Prosthetics
**Proprietary HP^® technology

The information contained herein is believed to be reliable, but no representations, guarantees or warranties of any kind are made as to its accuracy, suitability for particular applications or the results to be obtained. The information is based on laboratory work with small-scale equipment and does not necessarily indicate end product performance. Because of the variations in methods, conditions and equipment used commercially in processing these materials, no warranties or guarantees are made as to the suitability of the products for the applications disclosed. Full-scale testing and end product performance are the responsibility of the user. Lubrizol Advanced Materials, Inc. shall not be liable for and the customer assumes all risk and liability of any use or handling of any material beyond Lubrizol Advanced Materials, Inc.’s direct control. The SELLER MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Nothing contained herein is to be considered as permission, recommendation, nor as an inducement to practice any patented invention without permission of the patent owner.

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TPU for Flexible and Durable Inner Prosthetic Sockets