Overview of the Initiative
A transformative project led by Quentin Sanders, an Assistant Professor of Mechanical Engineering and Bioengineering at the College of Engineering and Computing (CEC), has received a $502,222 grant from the National Science Foundation. The three-year initiative, titled “Fused Filament Fabrication of Customized Continuous Fiber Physical Activity Enabling Prostheses for Children with Lower Extremity Amputation,” seeks to bring high-performance, activity-minded prostheses within reach for children who have undergone lower-limb amputation.
The funding, which began in September 2025 and extends to late August 2028, underscores a growing emphasis on pediatric assistive devices that are not only functional but affordable and tailored to active lifestyles. Sanders collaborates with colleagues across mechanical engineering and bioengineering to tackle practical challenges in pediatric prosthetics using advanced manufacturing techniques.
Three Core Objectives
1) Understanding what drives a child to participate in physical activity
The project aims to identify both qualitative and quantitative factors that influence a child’s desire and ability to engage in physical activity. By assessing psychosocial and biomechanics-related demands, the team seeks to predict the specific prosthetic requirements that will support an active lifestyle. This objective addresses a key real-world need: prostheses that motivate participation in sports, play, and daily activities, rather than devices that merely replace a limb.
2) Linking child size, movement, and prosthetic mechanics
A second objective focuses on how variations in pediatric anthropometry and movement types affect the mechanical properties of running-specific prostheses. By capturing data on limb length, weight, gait patterns, and activity level, the researchers aim to optimize stiffness, energy return, and durability. The goal is to ensure that the prostheses can withstand dynamic activities—such as running and jumping—without compromising safety or comfort for growing children.
3) Comparing fabrication methods and performance under load
The third objective compares static and dynamic behavior of continuous fiber 3D-printed prostheses with conventional laminate designs under different load conditions. This analysis will help determine the viability of fused filament fabrication (FFF) with continuous fibers as a production approach for pediatric prosthetics. Outcomes will address manufacturing efficiency, material properties, and long-term wear characteristics critical to everyday use by active children.
Impact and Significance
By combining innovative material science, personalized design, and pediatric biomechanics, the project aims to reduce cost while increasing customization. The use of continuous fiber reinforcement in a fused filament fabrication workflow has the potential to deliver high-performance prostheses with lighter weights and better energy efficiency. If successful, the research could set new standards for how prosthetic devices are designed, manufactured, and prescribed for children across diverse activity levels.
What the Funding Enables
The NSF award supports research personnel, equipment access, and data collection necessary to address the three objectives. The timeline allows for iterative testing among controlled lab experiments and real-world activity scenarios, ensuring that findings translate into device designs, software tools, and potential clinical guidelines. The outcome may influence future standards in pediatric prosthetics and inspire broader adoption of additive manufacturing techniques in medical devices.
Looking Ahead
As the project progresses toward its late-2028 goals, the team will disseminate insights through peer-reviewed publications, conferences, and collaboration with clinical partners. The ultimate aspiration is to make high-performance, actively usable prostheses more affordable and accessible for children, supporting healthier, more engaged childhoods.
