Overview
A recent grant from the National Science Foundation is fueling a pioneering project in pediatric prosthetics. The funding, awarded to Dr. Quentin Sanders, an Assistant Professor of Mechanical Engineering and Bioengineering in the College of Engineering and Computing, supports the development of customized, continuous fiber, 3D-printed prostheses designed to be more affordable, accessible, and tailored to the needs of active children with lower-extremity amputation. The three-year project seeks to unlock higher performance without sacrificing comfort or cost, ultimately expanding options for young wearers and their families.
Project title and goals
The project, titled “Fused Filament Fabrication of Customized Continuous Fiber Physical Activity Enabling Prostheses for Children with Lower Extremity Amputation,” centers on fused filament fabrication (FFF), a form of 3D printing that can incorporate continuous fiber reinforcement into prosthetic components. The long-term objective is clear: make high-performance prosthetic limbs more affordable, accessible, and tailored to the needs of active children.
Three core objectives guiding the research
To progress toward the goal, the team has established three interconnected objectives:
- Understanding participation drivers: The researchers will identify qualitative and quantitative factors that influence a child’s desire to engage in physical activity. By predicting the activity-related demands on prosthetic devices, clinicians can better match components to each child’s lifestyle and goals.
- Anthropometry and propulsion performance: The study will quantify how a child’s body measurements (anthropometry) and the type of movement affect the mechanical properties of running-specific prostheses. Such insight is critical for optimizing prosthetic stiffness, energy return, and durability during dynamic activities like sprinting, jumping, or playground games.
- Comparative analysis of materials under load: The project will compare static and dynamic behavior of continuous fiber 3D-printed devices with conventional laminate prostheses across different load scenarios. This side-by-side assessment aims to reveal advantages, trade-offs, and potential limitations of the new manufacturing approach.
Why continuous fiber FFF matters for pediatric prosthetics
Continuous fiber reinforcement combines the best features of 3D printing and traditional composites. In pediatric contexts, this approach promises several benefits: improved energy storage and return, greater strength-to-weight ratios, and the potential for rapid customization. For families, the technology could translate into lower costs, shorter prototyping cycles, and prosthetic limbs that better accommodate growth and changing activity levels as children mature.
Funding and timeline
The National Science Foundation has awarded $502,222 to support this research, with funding commencing in September 2025 and concluding in late August 2028. The financial backing demonstrates a strong endorsement of using advanced manufacturing methods, like FFF with continuous fiber reinforcements, to meet real-world clinical and social needs for young amputees.
Implications for clinical practice and accessibility
As the project advances, clinicians may gain evidence-based guidelines for selecting materials and design strategies that balance performance with comfort and durability. If successful, the workflow could streamline prosthesis customization for children in diverse settings—from urban clinics to rural programs—thereby broadening access to high-performance devices that empower young athletes and active students alike.
Looking ahead
Early results will likely shape subsequent design iterations and inform partnerships with hospitals, rehabilitation centers, and industry collaborators. The overarching aim remains to deliver a pediatric prosthetic option that not only supports physical activity but also adapts as children grow, ensuring better long-term outcomes and improved quality of life for families navigating limb loss.
