3D Printed Prosthetics: Empowering Mobility for the Underserved

With the rise of 3‑D printing and advanced manufacturing materials, innovators in the mobility sector are now able to deliver higher independence and a better quality of life to amputees and individuals with neurological conditions.

Millions worldwide rely on prosthetics and mobility devices to navigate their environments. Yet, access to reliable prosthetic care is uneven across the globe. According to the World Health Organization, only 1 in 10 people in low‑resource areas can obtain adequate prosthetic technology.

Engineers and clinicians are pushing the boundaries of additive manufacturing to produce durable, high‑functioning prosthetics at a fraction of the traditional cost. This breakthrough makes advanced mobility solutions more attainable for communities that have long been underserved.

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Toughware Prosthetics

Bradley Veatch, President and CEO of Colorado‑based Toughware Prosthetics, is dedicated to creating affordable, accessible prosthetics for underserved amputees.

For nearly two decades, Veatch employed cutting‑edge technology to design highly functional prosthetics. He recalls, “I was engineering success, but my device was so expensive that perhaps only ten people in the United States could afford it.”

That experience highlighted a critical need: the world required durable, affordable options rather than highly sophisticated, costly solutions. Veatch pivoted to develop prostheses tailored for developing countries—users who rely heavily on physical labor, lack reliable power supplies, or cannot easily access computers and other peripherals needed for more complex designs.

“I wanted to focus on technology that could truly meet everyday needs—swinging a hammer, carrying a 22‑pound bucket of water, or lifting a child,” Veatch explains.

However, the traditional prototyping workflow was a bottleneck. Complex parts had to be shipped out for machining, resulting in wait times of up to six weeks and stalling the entire design cycle.

The Solution

Veatch and his team invested in a Markforged composite printer capable of continuous carbon‑fiber printing. “As our projects demanded higher strength in certain components, this printer became essential,” he says.

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The Markforged printer has dramatically accelerated production. Veatch can design, print, and test a component within the same day, eliminating the six‑week delay of external machining. “I can print what I need, when I need it, and keep the iterative process tight,” he notes.

Cost savings are significant. A prototype bracket that would have cost $65 to machine from aluminum now prints for only a few dollars. The carbon‑fiber composite delivers the required strength, and the part finished in just five hours.

Thanks to rapid prototyping, Toughware can iterate quickly, refine designs, and bring high‑quality prosthetics to those who need them most, without long lead times or prohibitive expenses.