Episode #81 | From J&J to the Future: Sam Onukuri's 30-Year Adventure in 3D Printed Medical Devices

The Lattice (Official 3DHEALS Podcast)

Sam Onukuri takes us through his remarkable 30-year journey at Johnson & Johnson, where he transformed the landscape of medical devices through pioneering work in 3D printing technology. As a material scientist who led the development of J&J's Center of Excellence for additive manufacturing, Sam offers rare insights into how a global healthcare giant approached innovation and personalized medicine.
The conversation reveals the fascinating evolution of medical 3D printing from basic prototyping to FDA-approved implants. Sam shares the story behind breakthrough products, such as the TrueMatch graft cage – a PCL-based, bioabsorbable scaffold for bone reconstruction that has dramatically improved patient outcomes. His candid assessment of where personalization succeeds (craniomaxillofacial implants) and where it falls short (knee replacements) provides a nuanced perspective rarely found in technology discussions.
We examine the unexpected challenges that have shaped the industry, including the complex regulatory landscape, the emergence of surgical robots, and the economic realities that have tempered some early expectations. Sam's firsthand experience with point-of-care printing initiatives and customized surgical instruments provides valuable lessons about striking a balance between innovation and practicality in healthcare settings.
Looking toward the future, Sam identifies promising frontiers, including bioprinting, advancements in materials science, and the integration of AI with 3D printing technologies. For students and professionals considering careers in this field, he emphasizes the importance of strong engineering fundamentals and experiencing both startup and corporate environments to develop a comprehensive skill set.
Whether you're a healthcare professional, engineer, investor, or simply curious about how medical innovation occurs, this conversation offers an authentic glimpse into the triumphs, setbacks, and unrealized dreams that continue to shape the future of personalized medicine and additive manufacturing.

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1. Episode #81 | From J&J to the Future: Sam Onukuri's 30-Year Adventure in 3D Printed Medical Devices (00:00:00)

2. Sam Onokori's Career and Experience (00:00:01)

3. Establishing a 3D Printing Center of Excellence (00:08:50)

4. Successful 3D Printed Medical Products (00:17:37)

5. Personalization in Medical Devices (00:29:32)

6. Point-of-Care 3D Printing Evolution (00:38:32)

7. Future Directions in Medical 3D Printing (00:51:52)

8. Advice for the Next Generation (01:07:12)