2nd December 2025
For more than a decade, 3D printing has caused both excitement and misconceptions in the prosthetics world. Early headlines imagined a future where anyone with a hobby printer could benefit from 3D printed prosthetic limbs at home, with traditional fabrication methods outpaced by advanced designs.
Parts of that dream have been realized. At Open Bionics, nearly every part of our technology incorporates some element of 3D printing, from the test sockets and frames to structural design elements inside our bionic hands. The Hero Arm made history as the world’s first medically approved, 3D printed myoelectric prosthetic arm to receive FDA clearance. That milestone demonstrated that 3D printing could move beyond prototypes and aesthetic covers and into regulated, clinical-grade prosthetic devices—setting a new standard for modern prosthetics.
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“I print two test sockets from the same digital model, one based on conservative measurements and another designed for a more experimental fit,” he said. “Sometimes we end up going with the more aggressive modified one.”
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At our Austin prosthetic clinic, upper limb specialist Travis Heins has seen firsthand how 3D printing can elevate the experience of receiving a prosthetic arm from a drawn-out series of appointments into a streamlined, more predictable process. Instead of multiple rounds of casting, adjustments and travel to and from the clinic, Travis uses digital models and printed test sockets to refine his patient’s fit in a fraction of the time. For families who often drive hours to reach a preferred clinic or rearrange work schedules for each appointment, these efficiencies matter.
“I print two test sockets from the same digital model, one based on conservative measurements and another designed for a more experimental fit,” he said. “Sometimes we end up going with the more aggressive modified one.”
This approach gives patients a personalized fit without multiple rounds of manufacturing or travel.
Travis also uses 3D printed materials to closely replicate the feel of the final socket. “We print our test sockets in TPU, which lets us mimic the flexibility and compression of the final Hero FLEX socket,” he said. “It is significantly better than traditional methods for upper extremity care.”
Our Perfect Fit Promise ensures every user begins with a socket that feels right from the start. Each device comes with a fit adjustment period that allows clinicians to make any needed changes for a comfortable, secure fit. Our Hero Arm, Hero PRO and Hero RGD include a 60-day fit guarantee as part of HeroCare. All adjustments during this time are covered, and our clinical team works closely with each patient to make sure their socket supports everyday life.
Because our sockets and test sockets are created using precise digital design and 3D printing, clinicians can refine fit early and efficiently. This combination of modern fabrication and a guaranteed fit period helps users move forward with confidence and improves adoption rates.
By combining a detailed plaster cast with digital rectification and printed test sockets, clinicians can capture compression zones and contours that are difficult to reproduce by hand. These advancements do not lower costs within today’s insurance system, but they do improve the overall comfort levels for 3D prosthetic limbs. Families don’t have to feel like they are gambling on whether a high-tech device will fit comfortably. Clinicians can use digital tools and rapid fabrication to deliver a more predictable result from the start.
Beyond the fitting process, 3D printing prosthetic limbs have advanced significantly. Additive manufacturing allows engineers to build features that cannot be achieved with plaster, carbon fiber or thermoplastic alone.
Lightweight lattice structures reduce weight, ventilation channels improve airflow, and flexible geometry creates a more breathable and durable socket. These design elements make devices like Hero PRO or Hero RGD more comfortable for extended wear.
But 3D printing has not solved the larger systemic challenges. Insurance coverage remains one of the biggest hurdles to access the latest in 3D printed prosthetic care. Even though multiarticulating myoelectric devices have existed for decades, upper limb patients still face denials. And while 3D printing has transformed prosthetic design, it has not changed the price.
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“The healthcare system sets the price,” said Joel Gibbard, CEO and co-founder of Open Bionics. “Competition is then around who can provide the highest quality at that price.”
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“The healthcare system sets the price,” said Joel Gibbard, CEO and co-founder of Open Bionics. “Competition is then around who can provide the highest quality at that price.”
As long as reimbursement structures remain outdated, new devices will continue to be forced into old pricing models. The cost of prosthetic devices reflects insurance policies rather than technological progress.
“We have faced the same challenges many companies encounter when bringing new medical technology to market,” said Samantha Payne, co-founder of Open Bionics. “The U.S. healthcare reimbursement system creates barriers that make it difficult for people who want this technology to access it. Improving accessibility in prosthetics will require meaningful progress within the reimbursement system itself.”
Those challenges shaped how Open Bionics approaches access today. As 3D printing matured, we focused on building technology that fits within existing clinical pathways. “Most patients expect to use their insurance benefits,” Samantha said. “We’ve learned that sustainable access means aligning with existing clinical and reimbursement models, and supporting patients through it all. We also have multiple funding pathways in place for people seeking access outside of insurance, ensuring that there is a way for everybody to access advanced prosthetic devices.”
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“The solution to reduce healthcare costs and increase accessibility is not likely to be a technological one,” Joel said. “It requires systemic change.”
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While insurance remains the primary pathway for most users, our team continues to support amputees who do not have coverage or whose plans do not include upper-limb prosthetics. Through nonprofit partners, charitable foundations, grant programs, and fundraising assistance, families can be connected to alternative funding options. For pediatric patients in particular, these pathways can close gaps that insurance leaves open. This work is ongoing, and we continue to expand collaborations that help families secure the support they need.
Samantha added that clearer coverage rules could ease the burden on both providers and patients. “If coverage pathways become clearer and more consistent, the process becomes less stressful and may help reduce overall costs over time.” She emphasized that broadening access will depend on more than hardware innovation. “Policy, and contracting will play a major role in expanding access in the prosthetics industry.”
The promise of 3D printing remains real, but it is different from what early headlines predicted. It did not create low-cost prosthetics made on home printers. Instead, it enabled lighter, stronger, more breathable and more personalized devices that help increase the adoption rates of multitouch myoelectric devices while in turn enabling users to live more active, independent lives.
Looking ahead, equitable access will depend on policy reform, clearer reimbursement pathways and updated coding. “The solution to reduce healthcare costs and increase accessibility is not likely to be a technological one,” Joel said. “It requires systemic change.”
If you are interested in learning how a 3D printed bionic arm could help you reach your goals, sign up for a free consultation with our clinical team.
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