A Customer Story: ACULP

How ACULP is Redefining the Possible in Prosthetics

For over 70 years, the standard for making a prosthetic limb has been a process called socket lamination. It is a manual, labor-intensive craft involving plaster casting and harsh chemical resins. While this is the way things have always been done, Dan Dafonseca, Prosthetic Research Designer at the Atlantic Clinic for Upper Limb Prosthetics (ACULP), puts it bluntly: "It’s archaic".

Located within the University of New Brunswick’s Institute of Biomedical Engineering (IBME), ACULP’s mission is deeply rooted in engineering resilience. The clinic’s legacy dates back to the Thalidomide crisis of the 1960s, when a specialized research team formed specifically to help infants born with congenital limb differences. That original mission of solving complex upper-limb cases is what led the clinic to eventually leave traditional methods behind.

Today, by moving to a 90% digital workflow powered by HP Multi Jet Fusion (MFJ) technology, they have quadrupled their production speed and unlocked a level of personalization that was once impossible.

Dan Dafonseca, Prosthetic Research Designer, and Heather Daley, Research Prosthetist, ACULP

The Path of the "Arm Mechanic"

Dan’s transition into additive manufacturing wasn't a sudden corporate mandate. It was a journey driven by his own curiosity and a refusal to accept the limitations of the status quo. He started small, experimenting with desktop FDM printers for basic prototypes. Eventually, he began ordering MJF parts from service bureaus to test their strength and durability.

He quickly realized that to truly transform the clinic, he had to bring the technology in-house. But the transition involved a significant learning curve. In an industry where tradition is the default, Dan had to take the initiative to learn new software and hardware while navigating the "this is how it’s always been done" mentality.

For Dan, the turning point was a realization of the massive physical and mental toll required by traditional lamination. The old process is a high-stakes gamble; a single fabrication error or starvation in the resin can ruin a part at the very last second, instantly erasing many hours of labor. Between the risk of repetitive strain injuries and the inefficiency of "starting from scratch," Dan reached a point of no return.

"I sometimes ask, what would we do if the printer died all of a sudden?" Dan says. "I would never go back to lamination. I would order parts from a service bureau before I ever went back to that." This conviction is born from seeing the massive gap in quality between a hand-laminated socket and a digitally designed, MJF-printed device.

Digital Advantage: Precision Meets Speed

The shift to digital hasn't just saved Dan’s hands; it has improved the lives of the clinic’s patients. The workflow at ACULP is a masterclass in modern engineering. Dan uses a handheld portable scanner to capture the exact shape of a modified plaster mold, ensuring a perfect fit that respects sensitive pressure points.

He then designs the device in Geomagic Freeform using a haptic "Touch" device. This is a robotic arm that allows him to literally feel the digital model as he carves and shapes it on screen. Because the process is now 90% digital, the predictability is a massive relief. What could take many weeks of fabrication for a certain device now takes a couple of days.

The Story of Troy and His Many Arms

The true power of this technology is best seen in the story of Troy, a patient who came to ACULP after losing his arm in an industrial accident. Troy had originally sought help at a different clinic, but the traditional prosthetic he was given was heavy and exhausting to wear.

Because of his specific limb requirements, Troy’s device was heavy, and he wanted a way to remove the arm for a break without having to take off the entire socket, which sat under his clothes. When he asked if this was possible, he was told "no."

Refusing to accept that answer, Troy, a naturally handy person, built his own solution. He modified his prosthesis using a car seatbelt buckle and a cable, allowing him to unclick the arm and give his shoulder a rest whenever he needed. When Troy eventually heard about the work Dan was doing at ACULP, he decided to see if there was a more refined, industrial-grade version of his hack.

Dan went to work, using digital design to turn Troy’s makeshift idea into a sleek reality. He designed a custom, anti-rotational connecting piece with integrated wiring that allowed Troy to click his arm on and off in one quick motion, with all the electronics connecting automatically.

Because digital files are repeatable, Dan didn't just make one arm; he made a suite of them. Now, Troy has three different arms that all click into the same shoulder mount: one for daily use, and others specialized for the power tools he uses in his workshop.

This level of modularity and weight reduction has allowed Troy to go from wearing his arm for just two hours a day to more than ten hours without fatigue.

The Psychology of Personalization

One of the most vital aspects of the MJF workflow at ACULP is the ability to achieve high-fidelity aesthetics. For Dan and his team, the look of a prosthesis isn't just about "flair"; it’s a clinical necessity for patient connection and psychological well-being.

The digital process allows for a level of expressive customization that traditional methods couldn't touch. For children, this means turning a medical device into a point of pride by incorporating vibrant designs, like rainbows and unicorns, directly into the structure. For adults, the focus is often on achieving a sleek, modern finish or matching skin tones to help the device feel like a continuation of the person rather than an attachment.

"These perks have helped patients get excited about their devices," Dan notes. "It helps them feel more accepting of them and happy to show them off."

Advice to the O&P Industry

Despite the clear benefits, many Canadian clinics remain hesitant to adopt additive manufacturing. When asked what is holding the industry back, Dan doesn't pull his punches.

"The biggest anchor is definitely tradition, but time and money are a very close second," Dan says. He recognizes that for many, the sheer intimidation of the learning curve is what keeps them on the sidelines. "It’s a massive shift in how you work, and I understand why that’s intimidating, but slowly, the rest of the world is advancing forward. This leap is for those with the initiative and the desire to do more and do better for their patients."

Dan acknowledges that the transition requires a dedicated "champion" within the staff – someone willing to take ownership of the technology and navigate the initial facility modifications and training. But in his view, the cost of staying stagnant is far higher than the cost of moving forward.

A Partnership Built on Support

Transitioning a clinic to a high-tech digital lab requires more than just a printer. It requires a technical backbone. That is where the partnership with GoEngineer comes in.

The team at GoEngineer has become a vital support system that helps keep the clinic running if a challenge arises. Whether it’s exploring new material applications or providing the support needed to keep a complex operation moving, GoEngineer has stepped in as the enabler of ACULP’s innovation.

The Next Frontier

As ACULP looks toward the future, they aren't slowing down. Dan is already experimenting with various materials and technologies, including the potential for 3D printed silicone to create even more comfortable, life-like interfaces for his patients.

By pairing the deep history of the IBME with the specialized engineering support of GoEngineer, Dan and his team are building a future where prosthetics are lighter, more capable, and more human than ever before.

Ready to digitize your workflow?

Whether you are looking to reduce weight, increase production speed, or offer your patients a new level of customization, GoEngineer has the expertise to help you get there.

Contact our team* to learn more about our medical and O&P solutions.

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