Prosthetics users are relying on technicians who are working with antiquated tools.
Research
The first step was visiting three prosthetics manufacturing facilities around Cincinnati to understand the people, processes, and challenges involved. At the first two, I found the technicians to be hands-on "shop guys" who loved their work but were resistant to change, contrasting the polished image of the prosthetics industry. However, the final facility was at the forefront of technology, using depth sensors and 3D printers. Inspired by this, I aimed to help traditional technicians work more efficiently without needing costly, untested equipment.
Current State & Opportunity
Manual
Assisted
Opportunity Space
Automated
Current Pouring Workflow
The pouring of resin is done by eye. To avoid under-pouring, technicians must over-pour and use excessive amounts of resin. This, coupled with disposable cups, spoons, and plastic bags, means waste is high.
Pour Resin
Without proper safety equipment (respirators/masks, gloves, etc.) the resin and promoter are extremely toxic to the user. At the various clinics visited, no technicians wore safety equipment.
Add Promoter
Measurements are haphazard and consist of “eyeballing” proportions which, admittedly, often resulted in failure. This means repeating the entire process again and wasting material.
Mix & Pour
Design Goals
By automating the mixing process, measurements can be exact leading to higher prosthetics socket yield and less over-mixing for less waste.
Improve measurements
Resin is a messy business and containing the materials until the final delivery is key to avoiding toxic chemical exposure and sticky situations.
Contain the mess
The goal is not to shake up the whole industry, but to provide a meaningful step up without the need to drop thousands on a large scanning and printing setup.
Integrate into current workflow
Initial Architecture Sketching
Refined Sketching
3D Exploration
CMF Exploration
Brand Inspiration: Three Components
Resin
Pigment
Promoter
Brand Ideation Overview
Final Logo Lockup
Mix System
Mix Hand Tool
The on-board UI allows technicians to easily set up their system for optimized results for each use. User profiles can be created as well for specific patients to ensure a fully custom prosthetic is made.
UI for Proper Mix and Ratio
The proprietary air compressor works hand in hand with the screen UI/ smartphone app to deliver an exact mixture of resin and promoter for the correct use. This saves time for calibration, but the system can be used with any other air compressor system.
Proprietary Double Air Compressor
These large capacity resin and promoter allow an exact mixture for each pour without a need to over-mix and waste expensive materials. By containing the resin and promoters, workers are assured heightened safety.
Large Capacity Containers
Quick coupling connections allow the user to quickly engage and disengage the system from moving around in a shop environment, replacing promoter or resin jugs, or disengaging for storage.
Quick Coupling Connectors
For optimal performance, the user can and should remove the central maintenance channels to remove any blockages caused by the expected build up of resin that will harden in the tool over time.
Modular Maintainance
Pigment cartridges can be inserted to achieve a plethora of desired colors. The exact amount necessary to color the resin without weakening it is exuded. Once a pour is completed, the partially emptied cartridge can be reused.
Replaceable Pigment
By sliding back the top portion of the tool, a user can eject the used nozzle straight into the trash for easy cleanup. After ejection, it is easy to install a new nozzle of varying sizes for different pour scenarios.
Easy Eject Nozzles
