Individualized prostheses for children at CHLA

Children’s Hospital Los Angeles (CHLA) is using 3D printing technology specifically to improve medical care. In addition to creating anatomical models for surgical preparation, individualized prostheses are produced for children with hand and limb differences. The initiative is led by Satchel Clendenin, head of the 3D printing program at CHLA. Since the program was established last year, the team has been working with several hospital departments to develop various medical applications.

One focus of the program is preoperative planning. By 3D printing patient-specific models based on CT scans, surgeons can simulate procedures in advance, leading to better outcomes and shorter operating times. Studies show that this technology can reduce the time in the operating theatre by an average of 60 minutes, which also minimizes stress for patients.

“We’ve been looking at specific cases of kids with tibia or fibula deformities, brachial plexus issues, or wrist and forearm deformities, and we are able to take a patient’s computed tomography (CT) scan and turn it into an exact 3D model of that specific patient’s anatomy that we can print using materials that mimic human bone, skin, and other tissues.”

Another area of application is prostheses for children. In collaboration with the Jackie and Gene Autry Orthopedic Center, low-cost, personalized prostheses are produced from materials such as polylactide (PLA) and thermoplastic polyurethane (TPU). These models can be adapted to individual needs and produced in child-friendly colors or with themed designs. The 3D-printed prostheses are not only functional, but are also designed to boost children’s self-confidence.

“I was searching through news articles and different 3D printing outlets one day, and I stumbled upon Freehand, a club at USC that creates prosthetic hands for kids with limb differences,” Clendenin explains. “I looked into this club further and learned that there are full, open-source digital files for several models of prosthetic hands online, along with instruction manuals and toolkits to help with assembling the pieces of each hand after you print them. I realized that there could be an opportunity for us to use these files on a larger scale at CHLA.”

“If we give a child a more old-school hook prosthetic that other kids at school think looks scary, they may not use it,” Dr. Lightdale-Miric explains. Many prosthetics are also prohibitively expensive for families. “So about 50% of kids with hand differences choose not to ever use prosthetics and just adapt to their differences. But for those who might want to try prosthetics and explore the benefits that they can provide, we want to give them the best possible introduction to prosthetic hands.”

The initiative offers the prostheses free of charge to give families with financial restrictions access to high-quality aids. The offer was officially presented at the CATCH Holiday event in December 2024, and initial feedback from patients and parents has been positive. Future plans include expanding the variety of materials and working with schools to provide more children with adapted prostheses.

“You need a team of talented people who understand this technology and really know the patients to be able to provide effective prosthetics and improve functionality for the kids,” Dr. Lightdale-Miric says. “We are so fortunate to have that here at CHLA, and I think that uniquely positions our partnership to succeed.”