The Brief

3D Systems wanted to spread the word about their consumer-friendly 3D printer brand, Cubify. To that end, I wrote more than 100 blog posts and news stories about the latest innovations in the 3D printing world, from 3D-printed prosthetics to eco-friendly materials.

Prosthetic Paws: 3D Printers Help Animals to Walk Again (Blog Post)

For some people, 3D printing only seems to be good for plastic knick-knacks and knockoff jewelry, but its true potential is finally getting noticed. First, reports in the medical field demonstrated how specialized printers could create custom prosthetic limbs for less money than previous methods, with a portable machine that can be transported nearly anywhere in the world. And now, designers are beginning to take that concept into the animal kingdom.

Derby the puppy was born with extremely small forearms and no front paws, which made walking almost impossible for him until a few months ago. Often, when animal shelters encounter a congenital defect on this scale, they'll choose to end that animal's life instead of finding it a good home. That was Derby's fate, until the Peace and Paws rescue nonprofit saved him and a woman named Tara Anderson became his foster parent. As an employee of 3D Systems in Massachusetts, Anderson was familiar with recent medical breakthroughs in the 3D printing world and wanted to try a similar approach with her foster pup.

Before trying prosthetics, Derby got around with a huge wheel-based contraption that attached to the sides of his body. Similar to a wheelchair, the device allowed Derby to move but seriously limited his speed and abilities, because all of his forward momentum had to come from his hind legs. With her team, Anderson began designing prototypes of 3D models that would give Derby adequate support and flexibility to run freely with other dogs in the neighborhood.

To ensure that the design fit Derby's legs, the team gave the dog a CAT scan to assemble a detailed 3D shape from thousands of individual 2D photos. They also used conventional molded casts, which hardened around Derby's elbows and gave the designers another customized frame to work with. For the trial run, the team printed a few different designs and tested them on Derby's legs to see which provided easy mobility and extra support. They tried out two peg-like models and one that put weight on his elbows, settling with a cupped "loop" design that lets Derby run with ease and gives his legs some necessary cushioning.

Last August, the Portanova family adopted Derby in the middle of the printing process, working together with Anderson to help their pet adjust to his new legs. Today, Derby has no trouble keeping up with other dogs and playing to his heart's content. His prosthetic designs keep getting better, too, with the latest iteration sporting stronger treads, two more inches of height to match his hind legs, and the name "Derby" proudly engraved on the front. With a little ingenuity and some new technology, Derby was saved from death row and lives a happy life in New Hampshire with his loving family.