Ground Zero: Powder Bed Fusion for Prosthetics with David Pierick

The Prosthetics and Orthotics Podcast

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David Pierick, a retired Applications Engineer, shares the journey of bringing powder bed fusion technology to prosthetics and orthotics, revolutionizing patient comfort and outcomes through advanced materials.
• The initial challenge: proving 3D printed prosthetic components were as good or better than traditional methods
• Testing showed printed sockets were remarkably strong—in one test bending the aluminum testing rod before deforming the socket
• Patient feedback consistently reported greater comfort with PA-12 sockets, especially when paired with flexible interliners
• PA-11 offers superior fatigue properties and better strength-to-stiffness ratio than PA-12, though at higher cost
• PK5000 combines nylon stiffness with TPU softness, enabling thinner socket designs with excellent impact resistance
• Proper design principles are critical: avoid sharp edges, ensure proper radii on all features, and properly transition corrugations
• Future innovation requires thinking beyond traditional manufacturing constraints and adopting true 3D design approaches
• Collaborative teams of polymer experts, design specialists, and clinicians are essential for solving complex challenges
• New applications could include integrated functionality with shock absorption zones and varying flexibility in a single component
Special thanks to Advanced 3D for sponsoring this episode.
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1. Podcast Introduction and Spain Blackout (00:00:00)

2. Meet David Pyrrhic: Powder Bed Fusion Pioneer (00:02:45)

3. Testing and Validating Additive Manufacturing Solutions (00:06:10)

4. Market Challenges and Industry Adoption (00:11:55)

5. Material Advantages: PA-12, PA-11 and PK5000 (00:19:36)

6. Innovation in Design and Complex Structures (00:30:05)

7. Future of Materials and Collaboration (00:42:13)

8. Closing Thoughts and Takeaways (00:53:05)