[Poland Syndrome] Arm Fitted with a Custom 3D-Printed Bionic Prosthesis for Caiden

Sixteen-year-old Caiden spends his school days doing what most high school students do: hurrying between classes, carrying books, navigating crowded hallways, and trying not to spill his lunch tray. Born with Poland Syndrome, arm-related tasks often take extra planning.

Caiden grew up doing everything with one hand “It’s awkward to carry my lunch tray and try to pump ketchup,” he said. “Sometimes I’ll just ask a friend to do it for me.” As he got older, the strain became noticeable. He developed early arthritis in his right elbow, his shoulder began to hurt when he ran, and long school days often left his back feeling fatigued. He wanted a more balanced way to move through the world.

“I want to feel more evened out,” he said. “I want to grow muscle on both sides and stop putting all the pressure on my left arm.”

He first learned about Hero PRO through a family member living in Alaska. When he looked it up online, the futuristic design captured his imagination immediately. “It looked like something out of Terminator,” he said, laughing. “I thought it was really cool.”

Caiden plays soccer, golfs, and hopes to spend more time in the weight room. The idea of using a bionic arm for school and working out motivated him to pursue an evaluation. “There’s a lot I want to do that’s just easier with two hands,” he said. “I’m excited to lift weights and get stronger. And I want to get better at golf.”

To help Caiden meet those goals, the Open Bionics clinical and engineering teams needed to work closely together and think creatively.

When he arrived for his fitting at the Open Bionics clinic, certified prosthetist in Orlando Emily Shannon recognized right away that his arm would call for a highly personalized design. “Every limb presentation is unique in some way and needs a socket to match,” she said. “Caiden’s arm gave us an opportunity to design something completely custom and innovative, which is only possible with 3D printing.”

She explained that most prosthetic sockets are built from standardized shapes that work well for many people but do not always reflect the natural variation in real limbs. Caiden’s arm had its own contours and needed to slide into the device at a particular angle, so the usual approach was not going to give him the comfort or independence he wanted. Instead of fitting him into a template, Emily and the engineering team shaped the socket around him.

Emily prepares extensively for her fittings, especially when a patient may benefit from a more personalized solution. “Our attention to practicality matters even more when we’re working with someone who needs a more personalized design,” she said. “I like to have a couple of test sockets printed before the fitting so we can do a little problem solving. At Open Bionics we do not like to say no to anybody. We will figure out a way to make the socket work or do something a little creative.”

During Caiden’s appointment, he mentioned that a prosthesis he used as a child had a small opening at the bottom. That simple detail sparked the idea that shaped his final design. Emily shared the concept with the in-house configuration team, and because the clinicians and engineers work closely together, they were able to explore it immediately. They created a new cutout that allowed Caiden to bring his arm in at the right angle and settle into the socket smoothly.

Caiden slid his arm in and out repeatedly as the team refined the shape, making small adjustments after each attempt. After several rounds, the fit was comfortable and secure. Most importantly, he could put it on by himself. “Once he got it on, it looked great and felt secure,” Emily said. “And the most important part was that he could do it himself.”

Caiden felt the difference immediately. “It just slid on better,” he said. “It felt really good.”

His experience reflects something unique about Open Bionics clinics. Because the clinicians work directly with the engineers who build Hero PROs, they can solve problems quickly and try new ideas without long delays. The person doing the fitting can speak directly with the person building the device, which often turns a challenge into an opportunity for creative design.

Emily said that connection often determines whether a prosthesis becomes part of someone’s daily life. “Our patients get a direct line to the people who build their devices,” she said. “If something needs to be adjusted, we can respond immediately because we know both the technology and the person wearing it.”

For Caiden, that collaboration helped create a bionic arm that matches his goals. He is looking forward to navigating school more easily, opening doors and lockers without juggling everything, and carrying his lunch tray without help. At home, he expects the arm to help with cooking, cleaning, and chores that require two hands. He is also excited to use it while lifting weights, playing golf, and taking photos.

“I’m excited to use it for school and for sports,” he said. “I just want to feel more balanced.”

Emily believes Caiden’s socket shows what is possible when clinicians have the freedom to design around the individual rather than relying on fixed patterns. “We don’t like to say no,” she said. “If there’s a way to make something work, we’ll explore it.”

Thanks to advances in 3D printing, our clinical and engineering teams can shape a socket to someone’s natural contours and refine the design in real time. That collaboration is one of the clearest advantages of working directly with the clinical arm of a bionics manufacturer, where the people who build the device also help fit the person who will use it.

If your child was born with Poland syndrome with arm limb differences, and you want to know whether a Hero PRO could support your child’s goals, schedule a free video consultation and speak directly with a certified prosthetist who can walk you through your options.