We tend to assume that the traditional fiberglass cast provides the best solution to the stabilization of bones. In fact, however, the shortcomings of traditional casting only surface once alternatives are seen. 

In 2014, I tore my TFC ligament in my wrist, requiring surgery.  Working with my team at 3D Systems, we 3D scanned my arm pre-operatively, in order to create the base data model.  We then mapped onto this data the 'keep-out' zones of my arm, specifically, bloodflow, nerves, and bony prominences.  The goal was to create a minimal structure that would stabilize any motion of the hand with respect to the forearm.  Any material that did not contribute to this task was to be removed.

The result was a brace that allowed the skin to breathe.  I was able to apply hot and cold compresses directly the surgical site within days of the surgery.  I massaged the surgical area to minimize scar tissue buildup.  I applied scar-reduction cream to the incision, reducing it to a nearly unnoticeable mark.  I showered daily, and scuba dived in the cast two months into recovery.  I had acupuncture weekly to minimize discomfort.  All of these are awkward or impossible with traditional cast methods. Recovery with this cast was comfortable, hygienic, versatile, , and far superior to any cast ever created in the past.

Design : Scott Summit

Software : GeoMagic, Pro/Engineer Creo

Fabrication : 3D Systems Selective Laser Sintering

Materials : polyamide, tumbled

Press : http://www.fastcodesign.com/3049149/healing-injuries-could-be-better-thanks-to-this-3-d-printed-cast

In 2007, Anais became the first person - to the best of our knowledge - to be treated with a 3D printed fracture cast.  She had broken her radius bone, and it would require six weeks in a cast. 

We 3D scanned her arm to create the underlay geometry.  An SLA 3D print, though not by itself strong or appropriate for skin contact, was created and then plated with a copper/nickel blend, leaving it cool to the touch and easy to clean.  A second (the white brace) was printed using Selective Laser Sintering, and left as raw (tumbled) polyamide. 

Her arm healed well, and her friends were jealous of her treatment. As an added bonus, her named was left as a tan mark on her forearm.

These were the first ever leg casts, created for sisters aged 3 and 5, who broke their tibias tumbling down stairs.  The legs were scanned using an Artec 3D scanner, and hinged fracture casts were designed and printed.  The braces had extensive fenestration, allowing the sisters to play at the beach nearby, and bathe the sand from the cast upon their return home. 

These were our early efforts at fracture stabilization.  In following efforts, we sought to remove ever more material, leaving only what was required for adequate stabilization, and no more.  Less is more, in this case. 

Design : Scott Summit

Software : GeoMagic, Pro/Engineer Creo

Fabrication : 3D Systems Selective Laser Sintering

Materials : polyamide

2013.  3D Systems' Cube III was intended to set the bar for plug & play, consumer-focused 3D printers.  The Cube III allowed easy cartridge swapping, wireless interaction, and an overall friendly and functional interaction. 

Design : Scott Summit & Janne Kyttanen

Software : Pro/engineer Creo III

2014.  The Touch represents a significant price break in haptic devices.  Traditionally, such a product would cost nearly $10K, making it useful to professionals exclusively.  The Touch reduced the cost to $500, without sacrificing quality or user experience.

A haptic device allows users to interact with digital 3D geometry, while experiencing tactile feedback.  Using such a device, a user may sculpt, shape, carve, etc any geometry to their liking, as if they were shaping that form in their hands.  This product is used in medicine, animation, film making, sculpture, fine art, fashion, automotive design, and increasingly unexpected fields.

Concept : Ping Fu

Project Management & Design : Scott Summit

Industrial Design : Seth Astle

Software : Pro/Engineer Creo III

2014.  3D Scanning can connect the physical world to the digital, offering a range of opportunities.  Traditionally, this process was expensive, technical, and left to professionals.  The Sense turned the 3D scanning experience into a fun, easy, intuitive process, inviting many more players into this technology.

The Touch, Sense, and Cube were create as a suite of intercompatible products that embodied the 'digital thread'.  The design intent was to communicate this interoperability at a glance.

Concept : Ping Fu

Project Management & Design : Scott Summit

Industrial Design : Seth Astle

Software : Pro/Engineer Creo III

2008.  There will never be enough trained medical professionals to meet the global need for prosthetic limbs.  This means that the solution must be digital, must scale exponentially, and must avoid the human bottleneck.

This concept leg proved that a complex leg may be created by algorithm and 3D printed, entirely custom per user.  The geometry is based on a contralateral 3D scan, guaranteeing a recreation of body symmetry.  Complex knee and ankle joints are printed integrally at no burden to process or cost. 

This remains an ongoing project.

Design : Scott Summit

Software : GeoMagic, Pro/Engineer Creo

Fabrication : EOS Selective Laser Sintering

Materials : polyamide

This leg could be printed based only on a contralateral leg scan, along with additional biometric data.  Unlike the 'Polyaxial Study', this leg featured a single pivot for the knee.  Though less biomimetic, it offers a more robust assembly of parts.  36 ceramic bearings surround the knee mandrel, allowing a water-safe overall leg.  The knee's 'lockout' is allowed by a recreation of horse-and-buggy era integrated strap brake between the upper and lower leg.  This is activated by upward heel force; therefore, deactivated at the initiation of a forward lean for a step.

While this leg worked well as a prototype, and the concept remains intact, limitations were discovered through the process that challenge the viability of this direction for extensive deployment.  I have no doubt that, at some time in the near future, all prosthetic legs will be printed to order, extensive research remains to guarantee a viable complement to the human form.

Design : Scott Summit

Software : GeoMagic, Pro/Engineer Creo

Fabrication : 3D Systems Selective Laser Sintering

Materials : Duraform EX Black (polyamide)

2008.  This concept trans-femoral prosthetic leg explored the notion that the design of a prosthetic leg could challenge traditional notions of limb loss by considering the device as much a lifestyle product as a medical one.  By embodying the device with a sense of design and form, it invites engagement and connects the amputee with the world around. If something feels medical, then we can only think of it as a medical adjunct.  If it instead complements the human form, taste and style, then it evolves from medical stopgap into something more human. It generates excitement, not pity.

A piston is housed within the 'calf muscle' geometry, in order to dampen the swing of the lower leg.  The leather-wrapped fairing on the lower leg is removable, allowing the user to change the appearance of the leg with their mood.

Design : Scott Summit

Software : Pro/Engineer Creo III

Fabrication : SLS Polyamide, nickel/copper plated

Transfemoral Modular Polyaxial Study. 

This concept was created for the reopening of the Cooper Hewitt Museum, in December of 2015.  The leg was created with the survivor of a terrorist aircraft bombing, based on a 3D scan of his contralateral leg.  The knee pivot geometry was based on Joel Sadler's 'Jaipur Knee' pivot locations, guaranteeing a fluid, human gate with a robust overall geometry. 

With this leg, the force of the heel strike is dampened by groupings of 'leaf-spring' style geometric elements that act to store and release the kinetic energy.  The foot flexes throughout, similar to a human foot.  The thigh component is simply strong and light, as a dual-wall structure wrapped in lateral ribs can be. 

This leg remains in the permanent collection of the Cooper Hewitt Museum of NYC.

Design : Scott Summit

Software : GeoMagic, Pro/Engineer Creo

Fabrication : 3D Systems Selective Laser Sintering

Materials : polyamide

Fairings were created as an art/social experiment in 2008.  The goal was to rethink the nature of a prosthetic leg, embuing it with all the personalization of a bespoke fashion product, while recreating body symmetry on the wearer. A 3D scan of the contralateral leg creates symmetric reference geometry, and the wearer is queried for design and material input. 

Unexpected results emerged.  Athletes played sports again, since the fairing offered utility in soccer and other sports.  Amputees wore shorts or skirts again, since the leg was intended to be seen, not hidden.  Amputees interacted more with the people around them, since the leg suddenly invited questions and comments, instead of awkward avoidance.

Bespoke created these legs for soldiers, models, athletes, and people around the world over several years.  We sold the company to 3D Systems, who then licensed the technology to UNYQ, who continues to create fairings.

Design : Scott Summit

CAD : Pro/Engineer Creo III, Geomagic

Materials : Selective Laser Sintered polyamide, Stereolithography with copper/nickel plating, leather, ballistic nylon

2014.  This concept skateboard was created for exhibit at the Cooper Hewitt Museum, and went on display starting Dec 10, 2014.  The concept illustrates the possibilities enabled using 'topology optimization' software, a method where anticipated mechanical forces are input into software, and an optimized morphology results, based on recursive finite-element modeling.  Many possible outcomes are given, and the designer (Seth Astle) morphed successful embodiments into the final design. 

Although this concept was intended to explore a concept, this approach is gaining acceptance throughout the design and manufacturing world.  Aircraft parts, running shoes, robots, and spacecraft are now starting to use topology optimization to improve mechanical characteristics of vital parts.

Project concept and management : Scott Summit

Design : Seth Astle

Software : Inspires, Z-Brush

Fabrication : 3D Systems Selective Laser Sintering (deck), Arcam EBM printed titanium trucks

Materials : Laser Sintered Polyamide, Electron Beam Melted Titanium

Scoliosis is best treated by bracing the torso and spine over several years in order to force the spine into the correct orientation during the patient's period of skeletal maturity.  But traditional braces remain bulky, hot, and visually disturbing.  As a result, patients - 90% of whom are girls aged 8-12, refuse to wear the brace. 

This tells us that the medical imperative is to make the brace a product of design and fashion.  If the patient chooses willingly to wear the brace, then their likelihood of an effective outcome increases dramatically. So we set out to create a brace that was highly ventilated, discrete beneath clothing, and complimentary to the patient's sense of fashion.  To this end, we created a library of pattern choices, effectively giving the patient agency in the design of their own brace. 

The result is a brace that is invisible beneath clothing, comfortable in all weather, and visually appealing.  More importantly, the result was a brace that was worn for longer hours, leading to improved medical outcomes.  Medicine = Design = Technology.

Next-generation explorations included braces that would allow full flexure of the spine during treatment, while maintaining correct orientation.  These braces are now being created under license by UNYQ.

Design : Scott Summit, Dr Kenneth Trauner

Software : GeoMagic, Pro/Engineer Creo

Fabrication : 3D Systems Selective Laser Sintering

Materials : polyamide

2012. This is the first acoustic guitar to be 3D printed.  The concept included not only the fabrication of a guitar, but one where each guitar might be created by algorithm, self-designed to meet an intended acoustic outcome.  The guitar player, in this case, might one day 'design' the intended sound by adjusting tone, timbre, etc, while the script co-creates the guitar to suit.  The final guitar would then be printed on demand.

The body of the guitar was printed as a monocoque construction, where all components - ribs, sidewalls, structural bosses, etc - were geometrically integrated into a single form.  In this way, the nominal wall thickness varied throughout the body, adding stiffness where required, and inviting resonance as needed.  The resulting sound is as rich and full as a comparable wood guitar.

Design : Scott Summit

Software : Pro/Engineer Creo III

Fabrication : 3D Systems Selective Laser Sintering

Materials : Laser Sintered Polyamide (monocoque body), Nickel-plated photopolymer (soundhole cover), Direct Metal Laser Sintering (sterling silver headstock logo), DMLS Stainless Steel neck plat.

Press :

National Public Radio

The traditional Homunculus describes the uneven distribution of tactile sensory perception throughout the human body, by visually exaggerating the region in order to indicate its relevance.  The Global Homunculus, similarly depicts data based on disproportional geometry.  In this case, however, the data reflects global data, input from any spreadsheet referencing the 204 nations (debated) of earth.  The images shown show a 3D print of a parametric globe driven by the Global Happiness Index.  Future models will show longevity, GDP, immigration/emigration, The Peace Index, etc.  

When data becomes tangible, it loses its abstract and ephemeral quality.  It invites the user to explore, contemplate, and study in a way that on-screen data visualisation often cannot.  I created this globe for my son, hoping to encourage him to consider the world around him for all its complexity, far beyond the representations provided by the traditional globe.

2015.  My team worked with 2.6 seconds of a dolphin's sound, parsing the data in order to better understand it as a visual spectral graph. The spectral graph represented frequency, amplitude and time, with the color enhanced to better visualize the resulting geometry. 

We worked with dolphin researcher Jack Kassewitz to refine the process until we were able to discern specific shapes from the echolocation signatures, shown in the Cymascope images with the circular structure. 

More can be found at this link :

http://3dprint.com/109082/echolocation-3d-print-dolphins/

Project Management : Scott Summit

Design : Seth Astle

Software : Rhino, Grasshopper

Fabrication : 3D Systems 510

2015.  This concept explored a possible application of 3D printing in medical or home applications.  In this hypothetical case, a snake-style robotic gantry could 3D print directly on the human body, as needed for exo-skeletal bracing.  Although this is a fictitious exploration, the concept is being explored in various research environments currently, and is not beyond the realm of possibility.

Design : Scott Summit

Process : 3D Systems Selective Laser Sintered Polyamide

CAD : Pro/e Creo III

2012.  Ekso Bionics creates exo-skeletal robots that enable people with spinal cord injury to walk.  In this concept project, we worked closely with Ekso to create a highly customized hybrid robot that integrated the physical morphology of a specific user with the robot. 

The 'test pilot' was Amanda Boxtel, who was 3D scanned to provide the body reference geometry.  Designer Gustavo Fricke then modeled the interstitial parts that connected Amanda's body to the robot, allowing additional clearance for any parts that may result in bruising or circulation loss.  

The design had a secondary intent, which was to mitigate the utilitarian, robotic nature of Ekso's machine.  The forms were deliberately fluid and sculptural, slightly suggestive of musculature. 

We created a 'Loftstrand' style crutch as well, also using a combination of 3D scanning and printing.  This crutch offered far greater confirmation against the unique contours of hand and forearm, and resulted in a more stable overall stance.

Project Management : Scott Summit

Industrial Design : Gustavo Fricke

Software : Pro/engineer Creo III, GeoMagic

Fabrication : 3D Systems Selective Laser Sintering (SLS)

Material : Laser Sintered Polyamide

2015.  We explored a vision for where we would like to see in a 3D printed exo-skeleton. In this conceptual design for Ekso Bionics we proposed a mesh of 'swarming robots', creating a powered, 3D printed, exo-skeletal fabric that assists walking.

Though this shows a hypothetical example of a futuristic fabric, the concept is not beyond the realm of possibility.  Mesh structures based on the human form have been taken to great lengths (look at NERVOUS System's Kinetic Dress, for example).  And swarming robots are now a regular exploration in the robotics world. The vision is that this will one day replace the wheelchair, offering those with Spinal Cord Injury a natural, discrete, comfortable way to return to ambulatory life.

Project Management : Scott Summit

Industrial Design : Evan Kuester

Software : Grasshopper

Software : Grasshopper

I worked with Dr Julielynn Wong, of 3D4MD to create the first parametric models for Mallet Finger splints, driven by dimensions taken from the current list of astronauts about the ISS.  These would be used in the event of a 'finger jam', where precise splinting is required to ensure adequate recovery. These parts were printed aboard the ISS, using the Made In Space 3D printer.

2007.  The Discovery Channel featured concept ideation and development in its one-season show, 'Prototype This!'.  One episode was devoted to the vision of a 'firefighter of the future', where extreme first-responder gear would be 3D printed to order, based on a 3D scan of each firefighter's body to ensure optimal performance.  Though the idea was enhanced for TV, the concept remains relevant today, as this approach drives an increasing number of high-performance, custom gear.

More information and images from the show can be found here :

http://www.cnet.com/news/discovery-channel-to-bring-tv-glamour-to-product-prototyping/

Design : Scott Summit

Software : Pro/Engineer Creo

Fabrication : EOS Selective Laser Sintering

Material : Laser Sintered Polyamide

Palm Pilot 'Razor' Concept.  1998

This was the first concept in a study that later evolved into the Palm V.  It explored the first use of fluid, sculptural forms in a hand-held 'personal data assistant', and introduced anodized aluminum and leather into the otherwise plastic and technology driven aesthetic of the time.

CAD : Pro/Engineer

Project Management : Gavin Ivester

Industrial Design : Scott Summit

Think Outside.  2002

Think Outside created the first folding keyboard, aimed at the emerging portable device market.  The keyboard was constructed of MIM stainless and anodized aluminum, and featured a complex, multi-linkage closing motion. 

Industrial Design : Scott Summit

Engineering : Function Engineering

Digiscents.  2001

The iSmell, created by Digiscents, intended to offer high-definition smell, via internet.  An email or website, for example, might include embedded .snt files, which would activate the device to deliver a precise waft of scent on demand. 

Design : Scott Summit

CAD : Pro/engineer

Sun Microsystems.  1999.

Sun's effort at a UNIX-based, stylus-driven, convertible laptop.

Industrial Design : Scott Summit

Apple.  1997

Industrial Design : Scott Summit

CAD : Ashlar Vellum

Apple Monitor.  1995

Industrial Design : Scott Summit

CAD : Ashlar Vellum

Silicon Graphics Octane Workstation.  1994

Industrial Design : Scott Summit

CAD : Alias

Mixman Audio Controller.  1995

Industrial Design : Scott Summit

CAD : Pro/engineer

Xenote.  1998

Industrial Design : Scott Summit

CAD : Pro/engineer

Soju Vibes.  2006

Industrial Design : Scott Summit

CAD : Pro/engineer

Music Republic.  2005

Industrial Design : Scott Summit

CAD : Pro/engineer
 

Laser Analyzer (Client Undisclosed).  2005

The device was to be machined from aluminum billet, blocking the powerful internal laser from the outside world.  The concepts explored ways to give the device personality and identity.

CAD : Pro/Engineer

Industrial Design : Scott Summit, Josh Ferguson

Engineering : Andrew Poutiataine

Simple Devices Audio Suite.  2005

Industrial Design : Scott Summit, Caroline Flagiello

CAD : Pro/engineer

Tapwave.  1998

Tapwave challenged far larger game controller/PDA manufacturers with its hit product, the Zodiac.

Industrial Design : Scott Summit

CAD : Pro/engineer

Mobile PC Concept Model.  1999

Conceptual product suite for digital, connected, modular tools, projected 10 years out (from 1999).  This predated Apple's iPhone.

Industrial Design : Scott Summit

CAD : Pro/engineer