The Prosthetics and Orthotics Podcast

Send a text We explore how pricing, policy, and 3D printing are reshaping orthotics and prosthetics from the UK to the Gulf and across Africa. Hugh Sheridan shares hard truths about aid that bypasses clinics and a road map for sustainable, locally led care. • roots in shoe materials evolving into O&P supply chains • UK reimbursement pressures and the pivot to prefabs and 3D printing • UAE as a hub versus Saudi growth and privatisation • pediatric disability needs and cultural barriers to access • why direct aid can starve local clinics of patients and revenue • franchise-style partnerships as a sustainable aid model • China and Turkey’s rising role in components and materials • open materials, SLS/MJF economics, and avoiding lock-in • central fabrication versus in-clinic making and clinician psychology • direct scanning, hybrid workflows, and protecting clinical value Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text We trace how affordable, reliable material extrusion is changing prosthetics and orthotics—from student labs to jungle clinics—and why toolpaths, not just materials, will drive the next gains in comfort, strength and cost. Real patient stories show the economics and ethics of access at scale. • season launch and mission to improve patient outcomes • shift from tinkering to reliable, prosumer 3D printers • material extrusion vs FDM and why terminology matters • nonplanar layers, multimaterial potential, pellet economics • toward truly digital extrusion with better sensing and AI • application focus over generalization in O&P innovation • case study on low-cost pediatric prosthesis with reuse of CAD data • orthoses workflows moving toward “toaster-like” simplicity • education pathways as students learn on clinic-grade printers • materials outlook: TPU, TPE, silicone prospects, polycarbonate tradeoffs • variable density, air pockets, and hybrid fill strategies for comfort • polar kinematics and toolpath planning as the next frontier • print farms, software orchestration, and scaling production Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text We talk with Molly McCoy about turning dense policy into practical tools, writing notes that get covered, and why advocating coverage can improve outcomes. The focus stays on patient stories, shared decisions, and using the whole medical record to support care. • how clinician notes function as medical records and drive coverage • writing people-first justifications that explain medical necessity • using therapists’ and nurses’ notes to support decisions • drafting notes in real time to capture shared decision-making • where AI helps as a writing partner and where it harms • working with payers while advocating for policy change • why two devices enable both ADLs and true physical activity • reducing burnout through smarter workflows and legislation • telehealth access gains and state-level advocacy • flexible roles, job sharing, and retaining clinicians in O&P Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text Is this the lost episode? No, but there is some "old news". We dig into how O&P is changing fast: major acquisitions, new L codes, and a fresh vision for education that blends clinical reality with digital tools. Adrienne Hill shares a grounded path for students and clinicians to build skills without burning out. • Hanger’s acquisition of Point Designs and upper limb strategy • Medicare L codes momentum for partial hand coverage • Three education models and how to choose • Why residencies still define clinical growth • Embedding scanning, CAD, and 3D printing in coursework • Practical literacy vs making the "sausage" in-house • Shifts from plaster to digital and what’s realistic • Workflows that prevent burnout and improve retention • Ownership dreams, debt realities, and timing • The modified seven-year rule for career moves • How to pick residencies that fit your EQ and IQ • Going rural or high volume to accelerate learning • Broadening applicant pipelines and faculty needs If you need any help with additive manufacturing reach out to our sponsor, Advanced 3D. Support the show

Send us a text We break down how L code pricing is set, why crosswalk and gap-fill can fail innovators, and how appeals drain time and cash. Two case studies—Point Designs’ digits and Ethnocare’s volume system—expose how “divide by five” logic and invoice anchoring distort value, while 3D printing and hybrid workflows offer a path forward. • crosswalk vs gap-fill pricing methods and trade-offs • pitfalls of 99 miscellaneous codes and ALJ appeals • point designs digits priced against a mechanical hand • Ethnocare’s volume management tied to sock costs • framing comfort as adherence, safety and savings • click medical as a data-backed reimbursement win • Medicare recognizing 3D printing as manufacturing • desktop tpu print farms and reliability advances • hybrid workflows using load-bearing capture and automation • fragmentation in O&P advocacy and need for alignment Thank you for listening. We’re in 118 countries and nearing 35,000 listeners—keep learning with us and share the show. Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text We explore how foaming TPU, belt printers, and clinician-led automation can bring custom foot orthoses in-house, cut costs, and reduce lead times from weeks to hours. Fredrik from CADmed shares what actually works, what doesn’t, and how remote design plus per-pair pricing changes the game. • why automation increases clinician control rather than removes it • carving versus printing tradeoffs on speed, finish, and cost • foaming TPU benefits including smoother surfaces and less waste • belt printers for continuous TPU production and better surface feel • FDM advantages over powder bed fusion for insoles • practical lattices and gradients without overengineering • decentralizing production to clinics for faster delivery • remote design, slicing, and printer control with per-pair pricing • scaling systems for reliability, repeatability, and low friction Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text We trade trade-show gloss for real-world tactics, then lay out a three-step plan to bring 3D printing into O&P without risking patient care or cash flow. From Bambu-level starters to automated check sockets, we show how to start lean, learn fast, and scale what works. • Formnext’s shift from machines to applications • Materialise Bricks for modular workflows and costing • Multi-material metal, gradient parts, and smarter tooling • Affordable LPBF and the desktop print farm surge • Start with a low-cost printer and print clinic tools • Outsource complex adjustable sockets to free capacity • Automate transtibial check sockets for speed and margin • Scanner choices from budget to pro with trade-offs • A three-tier roadmap to adopt and scale digital O&P Special Thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text We record on the road to the mothership to fit a 3D-printed adjustable suction socket using AirFit casting and compare loaded scans to raw scans. David shares his crash-to-career journey, why adjustability matters for neuromas and daily volume, and what makes the Americus foot feel lighter and livelier than it looks. • AirFit casting under load versus direct scanning • Four-scan workflow and remote 3D fabrication • Suction plus adjustability for volume and hotspots • Flexible inner swaps for quick tuning • David’s neuroma history and fit lessons • Americus foot layup, split keel, and energy return • Social media as connector, career builder, and patient support • Choosing a prosthetist who listens and offers trials • Safety, waste, and smarter ovens in the lab • Why 3D printing speeds care and improves revenue cycle Find David: YouTube The Adventurous Amputee • LinkedIn David Slider • Instagram Pirate Peg Leg and The Adventurous Amputee Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text We sit down in the Guatemalan jungle with filmmaker Todd Biss to explore how craft, ethics, and faith shape stories that fund care and protect dignity. From ad-agency polish to nonprofit trust, we trace how small crews, better audio, and sharp editing turn hope into motion. • origins in photography and ad-agency production • defining success through beauty, trust and client outcomes • on-location logistics, tech scouting and studio control • nonprofit storytelling with trauma-aware practices • lighter gear, better mics and sensor gains • editing as a puzzle with multi-length deliverables • hooks that respect attention without hype • tripod versus handheld choices for tone • audio upgrades that elevate any video • clinic systems from forming to fitting • Adonis’s first steps and renewed hope • faith-driven work and why it matters • pricing, discounts and sustainable impact • where to find Todd Biss online Find Todd at “Todd Biss Productions” on Google, LinkedIn, and Instagram Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text Two sentences from PDAC can potentially change the course of manufacturing history for O & P: additive manufacturing is now explicitly acceptable for coding prosthetic devices that meet existing HCPCS descriptions. We unpack what that clarity means for clinicians, patients, vendors, and payers, and how to adopt 3D printing without tripping on compliance. • Why PDAC’s language ends the gray area for 3D‑printed prosthetics • What PDAC and DME MAC do and how they shape coding • How to match additive devices to existing L code descriptions • Documentation discipline to avoid denials and audits • FDA’s proactive stance and signals to industry • Medicare vs Medicare Advantage realities for reimbursement • When new codes help vs when they stall at zero pay • Scaling care amid workforce shortages using digital workflows • Using additive to improve fit, speed, and repeatability • Practical steps to start: scanning, CAD, materials, records Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text We share a personal update and then dive into how injuries, curiosity, and tough feedback shaped a modular myoelectric hand that is lighter, repairable in minutes, and priced for wider access. Ryan Saavedra of Alt-Bionics walks through additive manufacturing choices, PDAC approval, and a roadmap linking prosthetics with humanoid robotics. • user and clinician pain points shaping design choices • modular finger architecture for fast field repairs • nylon 12 and MJF for strength, weight, and cost • tolerancing to reduce lash and improve reliability • pricing philosophy, PDAC approval, and reimbursement nuance • EMG control foundations, firmware over AI for stability • balancing service bureaus vs in-house manufacturing • funding from bootstrap to mission-aligned investors • product roadmap focused on hands and higher DoF • cross-pollination between prosthetics and robotics Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text What if everything we think we know about human walking is oversimplified? In this episode, we sit down with Dr. Steven Gard a biomedical engineer and leading gait researcher. We unpack the real biomechanics behind prosthetic design. From artificial heart labs to O&P innovation, Dr. Gard shares surprising insights on: shock absorption and “energy return”soft tissue acts as a natural springischial containment, subischial, and elevated vacuum socketsno design is one-size-fits-allmicroprocessor knees and 3D printingengineering theory and clinical practiceWhether you’re a clinician, researcher, or just prosthetics-curious — this episode reframes gait in a way you’ve never heard before. Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text Credit card rewards expert Colin Stroud reveals how O&P practice owners can transform regular business expenses into valuable rewards through strategic credit card usage. He explains the mechanics behind credit card rewards systems and how business owners can maximize returns on spending they would do anyway. • Single practitioner O&P clinics typically spend $15,000-$20,000 monthly on components • Larger clinics can spend $100,000-$200,000 monthly, generating substantial reward potential • Credit cards offer both cash flow advantages and rewards generation simultaneously • Cash back options typically max out at 2-2.5% return on spending • Points-based flexible currencies can yield 5%+ returns when redeemed strategically for travel • Rewards are considered rebates rather than taxable income • Multi-owner practices can divide points proportionally among partners • LinkedIn content marketing has driven Colin's entire business growth without paid advertising • The "arbitrage opportunity" of points redemption delivers significantly higher value than cash back Visit Colin on LinkedIn (Colin Stroud - with one L) or at gosomewhereworld.com to access his free newsletter and guides on maximizing credit card rewards. Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text Brent Wright shares his experiences from the American Orthotic and Prosthetic Association (AOPA) conference, highlighting innovations in 3D printing, data-driven technologies, and revealing his groundbreaking polar printer project for prosthetic sockets. • AOPA attendance exceeded 2,000 people with 165 exhibitors including 30 new vendors • Digital Showcase featured case studies for prostheses and orthoses using scanning technology • Blasingtech impressed with 3D printing capabilities, producing foot orthoses in 30 minutes • AI-designed scoliosis braces are outperforming experienced clinicians with better correction angles • Radii's socket design algorithms now match skilled clinicians in patient comfort and feedback • Tennr software helps clinicians identify missing documentation needed for insurance approval • Brent reveals the "Vortex" - a polar printer with non-planar toolpaths creating sockets in under 2 hours • Non-planar polar printing produces significantly stronger sockets than traditional layer printing • Vortex printers are already in production with three units being prepared for clinical testing Special thanks to Advanced 3D for sponsoring this episode! If you are interested in the Vortex DS1 please follow this link: Vortex DS1 3D Printer - Advanced 3D Support the show

Send us a text We catch up with Niles from Leonard Industries, our first-ever returning guest, as he reveals game-changing innovations in prosthetic and orthotic fabrication technology. This episode explores how new manufacturing tools are making fabrication faster, safer, and more consistent while helping address the industry's technical workforce challenges. • Leonard Industries has expanded by acquiring a machine shop with enhanced capabilities • Their revolutionary Wave Oven cuts heating time from 20 to 7 minutes using targeted infrared technology • The oven creates consistent results with wider work windows, eliminating the need to flip materials • Safety innovations include emergency stops, magnetic starters, and controlled heating • Multiple oven models accommodate different fabrication needs, from standard to large KFO applications • The "toast test" demonstrates heating consistency by showing how evenly bread slices brown • Leonard Industries will showcase their technology at the upcoming AOPA conference • The company has helped establish safer educational environments at O&P schools • Niles emphasizes making fabrication more accessible to new technicians through consistency and automation • Their aluminum construction ovens use less energy while providing more precise heating control Visit the Leonard Industries booth at AOPA to see live demonstrations of their new fabrication technology, including the Wave Oven, dust collection systems, and fume extractors. Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text We preview the upcoming AOPA National Assembly in Orlando, discussing what makes this prosthetics and orthotics trade show valuable for professionals across the industry. • AOPA (American Orthotic and Prosthetic Association) National Assembly happening September 3-6 in Orlando, Florida • 165+ exhibitors representing various aspects of the O&P industry • Educational tracks covering clinical, technical, business, and pedorthic topics • Up to 34 continuing education credits available in person, with 100+ hours of online content afterward • Hands-on technical laboratory for fabrication techniques and safety equipment demonstrations • Digital Showcase featuring case studies and workflow solutions from different vendors • Administrative Law Judge mock trial simulating insurance appeal processes • Strong 3D printing presence with 33+ companies showcasing additive manufacturing solutions • Notable exhibitors including long-established companies and first-time participants • Importance of consistency at trade shows for building relationships and trust in the industry • Networking opportunities that facilitate business connections and partnerships Join us at the Prosthetics and Orthotics Podcast booth where we'll be broadcasting live throughout the event! Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text Brad Matear, who oversees central fabrication for Shriners Children's hospitals, shares insights on the technical side of O&P, highlighting the critical shortage of trained technicians and pathways for advancing the profession. • Shriners Children's central fabrication serves approximately 19 facilities nationwide, dealing with complex pediatric cases that require exceptional technical skill • The field faces a serious technical talent shortage with 15-16 clinical schools but only 4 technical schools producing graduates • Technician compensation and recognition are crucial factors in retention, with approximately 30% attrition rate compared to clinicians • Digital fabrication including CAD/CAM and 3D printing represents the future for technicians, requiring new educational approaches • The Assistant Credential offers a promising middle path between technical and clinical roles, similar to the PT/PTA model • Technical education must evolve to include both traditional hand skills and advanced digital techniques • AOPA 2025 in Orlando will feature hands-on technical education including custom fabrication and alignment techniques • Proper disposal and recycling of materials remains a challenge, particularly for foam products used in fabrication Please recycle your plastics as best you can and if you're an engineer with ideas for recycling carving foam, the industry needs your solutions to reduce landfill waste. Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text Rich Dubin, CEO of LER Expo, shares his journey creating digital educational platforms that foster cross-disciplinary learning for healthcare professionals in the lower extremity market. We discuss how bringing together specialists from different fields—from podiatry to orthotics and prosthetics—leads to better patient outcomes and more innovative approaches to care. • Founded LER Expo in 2019, perfectly timed before COVID shut down in-person educational events • Created an engaging digital conference platform that recreates the in-person experience with lobbies, exhibit halls, and networking spaces • Uses innovative approaches like tournament-style presentations to keep audience engagement high • Emphasizes the importance of cross-disciplinary education across healthcare specialties • Discusses concerns about the rising cost of O&P education with master's programs approaching $200,000 in total costs • Highlights the critical value of mentorship and hands-on experience versus academic credentials alone • Shares practical advice for clinicians wanting to present at virtual conferences • Believes collaborative care across disciplines leads to better outcomes for patients • Encourages professionals to look beyond their specialty silos to find new connections and innovations Special thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text We explore the exciting intersection of engineering, biomechanics, and 3D printing in prosthetics with our guest Ashton Stoop, who shares his journey from mechanical engineering student to designing 3D-printed prosthetic limbs in Mexico. • Ashton's background in mechanical engineering and his path to O&P through biomechanics research • The importance of both functionality and emotional integration in prosthetic design • How custom prosthetic covers serve as tools for patient acceptance and identity • Using Rhino and Grasshopper software to create automated workflows for socket design • The balance between maintaining clinical control and leveraging AI automation • The potential for 3D printing to democratize the prosthetics industry • How small clinics can compete with larger corporations through innovative technology • The critical importance of clinical evaluation and fitting despite technological advances • Challenges in biomechanical understanding of complex structures like feet and ankles • Community initiatives like the Digital Limb Collective that share knowledge and best practices The field of prosthetics needs professionals from all backgrounds – you don't have to be a clinician to make a difference in people's lives. If you have design skills and a passion to help others, there is room for you to contribute to this meaningful work. Special Thanks to Advanced 3D for sponsoring this episode. Support the show

Send us a text Dhruv Agrawal, founder of Aether Biomedical, shares how a birthday gift 3D printer led him from medical school to developing the Zeus hand, the strongest bionic prosthetic hand on the market with revolutionary cloud-based tracking capabilities. • Journey from medical student to prosthetics innovator began with a 3D printer birthday gift • Uses additive manufacturing not just for prototyping but for actual production components • Zeus hand features industry-leading grip strength and 30-minute repair capability • Cloud-based platform tracks usage data, showing super users complete 700-800 grip cycles daily • Data collected helps optimize device settings and provides evidence for insurance authorization • Most users rely on 4-6 standard grips plus 2-3 customized grips for specific activities • Currently working on multiple versions of the Zeus hand at different price points • Long-term vision is to become "the operating system for assistive devices" across prosthetics, orthotics, and exoskeletons • Company of 60 people with half dedicated to research and development • Future developments include VR training tools for phantom limb pain management Special thanks to Advanced 3D for sponsoring this episode. Support the show