BASF and Essentium, Inc., under its subsidiary brand TriFusion
Devices, bring the strongest 3D printed thermoplastic carbon fiber
definitive prosthetic socket to market that is easily customized to
ensure the most comfortable fit for patients.
The prosthetic, printed with BASF’s Ultramid® polyamide
reinforced with short carbon fiber, is lightweight, yet tough and
more flexible than traditional carbon fiber sockets. The definitive
socket is made with thermoplastic material that enables small
adjustments in increments of 2-3mm without weakening as needed
throughout the life cycle of the prosthetic, a crucial development
as a patient’s body changes over time. While traditional sockets do
not easily accommodate modifications, BASF’s material allows
changes to be made directly to the socket to ensure it always fits
a patient comfortably.
“It’s a rewarding process to develop the formulation in the lab
with Essentium and then turn that resin into a real material,
knowing it can impact prosthetic patients in a positive way,” said
Oleksandra Korotchuk, New Market Development Scout, Performance
Materials at BASF. “It’s a true validation of the partnership and
we will continue to uncover new materials and techniques that will
unlock advanced design and speed capabilities.”
To ensure the sockets meet clinicians and patients’
expectations, the companies enlisted Anew Life Prosthetics and
Orthotics, a Southeast Mich. based clinic, as a validation partner.
BASF introduced Essentium to Chris Casteel, owner of Anew Life, to
determine the fit and function of TriFusion 3D printed sockets. As
a clinician, past manufacturing professional and amputee himself,
Casteel works with patients to test the sockets and provide
real-time feedback to Essentium and BASF on improvements to the 3D
printing process and material selection. According to Casteel,
patients shared that the test sockets fit like a glove and are
overall more comfortable.
“Just like anything else, it’s one thing to hear about a product
like this, but another thing to actually feel and touch it,”
Casteel said. “We received extremely positive feedback from
patients on the 3D printed test sockets and it is incredible to see
and feel how well they fit. This is a huge success for the
prosthetic industry and I look forward to seeing what comes
next.”
Patient safety and satisfaction are of utmost importance, so
while the development of 3D printed prosthetic devices is not yet
regulated by the FDA, Essentium and BASF choose to follow the
strict standards outlined in the regulatory body’s guidelines for
Additive Manufacturing set forth December, 2017. Each of the
30-step manufacturing process is documented and the devices are
hand inspected before being shipped to clinicians.
A traditional carbon fiber socket typically takes three days of
labor by a technician to mold and cast. The 3D printed socket
streamlines the time- and resource-intensive production process to
less than 24 hours from scan to ship. This allows for efficient
order fulfillment, increased patient interface and profitability
for clinicians. It also eliminates human error as the scan ensures
the socket fit is close to correct the first time.
“The materials used in these definitive sockets have the power
to open up people’s lives to more mobility and more freedom,” said
Blake Teipel, president and co-founder of Essentium, Inc. “As we
propel 3D printing of functional parts, we’re proud to make a
prosthetic that’s more customized, lightweight, affordable and
comfortable for the patient, and make the production process easier
and more efficient for the clinician.”
The companies are also actively pursuing the production of a
multi-material 3D printed prosthetic with rigid and flexible TPU
elements. The hard-soft socket would allow clinicians to implement
soft material into the design for increased comfort on sensitive
areas. It is expected to launch in 2018.
The 3D printed prosthetic leg, with the carbon fiber definitive
socket and foot, will be on display at NPE 2018.
For a press photo, please click the following link:
https://www.basf.com/press-photos/us/en/photos/2018/04/04-18-18_3DPProstheticLegBASFEssentium.jpg
Suggested caption: 3D printed prosthetic leg by
Essentium, Inc., featuring BASF composite polyamide materials.
About BASFBASF Corporation, headquartered in
Florham Park, New Jersey, is the North American affiliate of BASF
SE, Ludwigshafen, Germany. BASF has more than 18,200 employees in
North America, and had sales of $17.9 billion in 2017. For more
information about BASF’s North American operations, visit
www.basf.com.
At BASF, we create chemistry for a sustainable future. We
combine economic success with environmental protection and social
responsibility. The more than 115,000 employees in the BASF Group
work on contributing to the success of our customers in nearly all
sectors and almost every country in the world. Our portfolio is
organized into five segments: Chemicals, Performance Products,
Functional Materials & Solutions, Agricultural Solutions and
Oil & Gas. BASF generated sales of €64.5 billion in 2017. BASF
shares are traded on the stock exchanges in Frankfurt (BAS), London
(BFA) and Zurich (BAS). Further information at www.basf.com.
About Essentium, Inc.As innovators in both
materials and production systems, Essentium is committed to
creating industrial solutions for the world’s top manufacturers. It
is providing a new generation of 3D industrial solutions with
performance, efficiency, and economics in mind. Later on this year
Essentium will release an industrial machine that will be ten times
faster and more accurate than any other printer on the market
allowing manufacturers to finally be able to produce at
scale. Read more at www.essentium3d.com.
TriFusion Devices, a subsidiary brand of
Essentium, is utilizing FlashFuseTM technology to revolutionize the
orthotic and prosthetic industry by offering 100% customized, 3D
printed structural and in-clinic prosthetic and orthotic devices.
Read more at www.trifusiondevices.com.
About Anew Life Prosthetics and
OrthoticsAnew Life Prosthetics and Orthotics is committed
to providing each patient with an exceptional level of care and
attention. At Anew Life Prosthetics and Orthotics, we are proud to
be practitioner owned and operated. Our dedicated staff works
together as a team to provide high-quality comprehensive care. Our
compassionate and understanding practitioners take pride in paying
close attention to each patient's needs. When you are ready to take
charge and return to life following limb loss please contact Anew
Life Prosthetics and Orthotics. We provide prosthetic (artificial
limb) or orthotic (brace) devices. Our Detroit office is open and
we are currently accepting patients. Thank you and remember that
there is life after limb loss. Read more at
http://www.anewlifepando.com/.
Susan Jackson
734-324-6546susan.jackson@basf.com |
Maria
Violette248-203-8126mviolette@webershandwick.com |
BASF Corporation1609
Biddle AvenueWyandotte, MI 48192www.basf.com |