The TTA team recently sat down to speak with Albert Manero, Executive Director of Limbitless Solutions, a nonprofit research facility at the University of Central Florida (UCF) that 3D prints bionic limbs for children.

Origins and Mission

Founded in 2014, Limbitless Solutions aims to empower the limb difference community with accessible muscle-based biosensing technology. The organization creates multi-gesture bionic arms, hands-free wheelchair controls, and interactive video-game training. One of their first projects was a 3D-printed, electromyographic fully actuated Iron Man-themed bionic arm, presented to young Alex Pring by Robert Downey Jr.

“For us at Limbitless, our heart is to be able to build both expressive and beautiful bionic arms that also function in a really meaningful way for our bionic kids. And a lot of the families that we work with have described how difficult it is for children to get access to prosthetics. And that’s what we’re trying to do–to use advanced manufacturing techniques to be able to make a bionic arm that kids really enjoy using and expressing themselves with, that we can make it a cost point where we can donate every device to every family that needs it,” says Manero.

He continues, “10 years ago, we would never have imagined that we’d have the opportunity to continue to work towards building bionic limbs and how much the technology would allow us to be able to create something from a whole new design perspective.”

The Process of Creating Bionic Limbs with 3D Technology

When Limbitless was first starting this project, Manero made a phone call to Stratasys, who manufactures 3D printers. Fast forward 10 years, and Stratasys has become one of their longest partners, supporting the 3D printing machines.

This is where TTA comes in. Through Stratasys’s partnership with TTA, TTA has been able to help maintain the 3D printing devices over the course of the partnership, which has been invaluable to keep everything up & running. 

Customization and Personalization

We asked Manero, “How do you customize and personalize this journey as much as you personalize this prosthetic?”

3D printing allows extensive customization and personalization, enabling each limb to be tailored to the recipient’s specific needs and preferences.

Manero explained, “At first, we thought kids just wanted to blend in, but it turns out it’s much more about personal identity and expression. We use a lot of 3D printing to be able to tailor the device specifically for our Bionic Kid that is going to be receiving it. Through our web portal, the family can actually go on and co-design by picking from different designs in our catalog and then choosing from different color palettes or being able to select the colors in different parts of their arm in order to get the design to match their expression as closely as possible.”

Technological Advancements

Advancements in 3D printing technology have revolutionized the prosthetics industry, enabling the production of highly personalized and functional prosthetic limbs at a fraction of the traditional cost. This technology has significantly reduced financial barriers for families.

“For us, it started with trying to re-imagine what a prosthetic limb could look like, how it would function, and then what its role was for a user, whether that was in a classroom, or on a playground. And being able to work with 3D printing, we were able to really maximize the uniqueness of each device, the fit and the customization for each patient, and ultimately see it grow with rapid prototyping to where we are today,” said Manero.

We asked Manero, “What are some upcoming innovations or bionic technology that Limbitless is working on currently?”

Limbitless is currently in the middle of a new clinical trial with Orlando Health, working on a new version of the bionic arm that uses a combination of injection molding, 3D printing, and vacuum forming. This would enable the team to develop the devices at a larger scale. The design and production of the bionic arm has continued to evolve, with co-founder John Sparkman leading the charge

“As technology continues to evolve, we look forward to further advancements that will enhance our ability to create even more sophisticated and accessible bionic solutions. Our ongoing clinical trials and research into new materials and manufacturing techniques hold promise for the future of bionics, ensuring that we can continue making a difference through cutting-edge technology,” says Manero.

In addition to 3D printing, Limbitless integrates advanced technologies like electromyography (EMG) sensors, which allow the bionic limbs to respond to muscle signals, improving functionality and user experience. These innovations enable users to achieve greater independence and a higher quality of life. 

Limbitless also creates its own video games and uniquely leverages video game-based training that converts muscle flexing into the video game character’s actions, led by UCF faculty members Matt Dombrowski with UCF’s School of Visual Arts and Design (SVAD) and Peter Smith with UCF’s Nicholson School of Communication and Media.

Impacting Daily Lives

Children with limb differences may face a variety of challenges in their daily lives, including difficulties in performing everyday tasks, such as eating, dressing, and playing, which might lead to frustration and a sense of dependence on others.

More than 32,500 children in the US have experienced a major pediatric amputation. (Source: Cignini, nih.gov)

Socially, they may encounter stigma and bullying from peers, which can impact their self-esteem and confidence. Additionally, access to prosthetics is often limited due to high costs, with myoelectric hands costing between $20,000 and $30,000, and neuroprosthetic arms costing up to $100,000. These financial barriers make it difficult for families to obtain the necessary prosthetics, further limiting the child’s ability to participate fully in daily activities and social interactions.

Limbitless Solutions has impacted numerous children, offering them not only functional bionic limbs but also a sense of confidence. It’s been 10 years since that first bionic arm delivery. Alex, the recipient of the first bionic arm, is now in high school and he plays on his high school football team. Alex has become an advocate for the organization, sharing his experience and inspiring others.

Another inspiring example is ten-year-old Julianna Linton, who received a 3D printed bionic arm from Limbitless Solutions. Julianna, a competitive cheerleader, was able to meet the UCF cheerleading team, performing stunts & cartwheels.

Supporting Limbitless Solutions

Limbitless Solutions provides bionic limbs to children without cost to families, even including travel stipends for clinical trials. Looking to offer support? This is welcomed, through donations, volunteering & spreading awareness. More information is available on their website at 3Dhope.com.