Dynamic 3D Printed Knee Orthoses with Dave Johnson

The Prosthetics and Orthotics Podcast

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Maybe the solution to your knee pain is a high-tech 3D-printed brace inspired by an injury from the football field. Today, we’re talking to Dave Johnson, the CEO and founder of the startup Icarus Medical, about his unusual path from a childhood on a dairy farm to inventing innovative knee braces. Dave describes how his life journey and a successful career in chemical engineering for the Department of Defense provided the inspiration for developing a high-performance, metal-free knee brace for fighting patellofemoral osteoarthritis.
And 3D printing how? Dave provides an ingenious step-by-step, from the first heavy, bulky prototypes to their eventual lightweight, contour-fit, form-fitting incarnation. His descriptions of the iterative development, including his incorporation of an elastomeric band to improve fit and tolerance, as well as the employment of a biomedical engineering intern, are both fascinating and informative. Moreover, he recounts how his team realised that the heaviest components came from the support material used in the printing process and, thus, shifted to Multi-Jet Fusion technology, which is cheaper and can be produced in much shorter runs. By the time we had finished, we wondered whether perhaps the biggest takeaway was that these state-of-the-art, individualised, contour-fit, 3D-printed, durable, adjustable, lightweight knee braces for leverage-control osteoarthritis became economically viable in greater number because of the strategic application of HP’s Multi-Jet Fusion technology.
But as much as it’s about the tech and engineering, it’s also about the people who are running the ship. In this episode, we spotlight the empathetic, patient-centric culture at Icarus Medical, where no two braces are ever the same, and every person is accommodated for, because – simply put – they can be. Dave takes us through the extensive process of getting a custom brace, from scanning to finishing to quality control to shipping, and into the nitty‑gritty of maintaining good relationships with outsourced contractors. And along the way, Dave shares some of his hard-won lessons on cost management, market research, and the power of staying true to your vision and having conviction in your product. If you’re at all interested in technology, medicine and innovation, you do not want to miss this episode.
This episode is brought to you by Advanced 3D.

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1. Innovative Knee Brace Design Journey (00:00:00)

2. 3D Printing Advancements in Knee Braces (00:08:20)

3. 3D Printed Knee Braces (00:17:31)

4. Empathy-Driven Custom Knee Brace Development (00:22:28)

5. Custom 3D Printed Knee Brace System (00:35:11)

6. Entrepreneurial Journey in Med Tech (00:47:03)