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We trace how affordable, reliable material extrusion is changing prosthetics and orthotics—from student labs to jungle clinics—and why toolpaths, not just materials, will drive the next gains in comfort, strength and cost. Real patient stories show the economics and ethics of access at scale.

• season launch and mission to improve patient outcomes
• shift from tinkering to reliable, prosumer 3D printers
• material extrusion vs FDM and why terminology matters
• nonplanar layers, multimaterial potential, pellet economics
• toward truly digital extrusion with better sensing and AI
• application focus over generalization in O&P innovation
• case study on low-cost pediatric prosthesis with reuse of CAD data
• orthoses workflows moving toward “toaster-like” simplicity
• education pathways as students learn on clinic-grade printers
• materials outlook: TPU, TPE, silicone prospects, polycarbonate tradeoffs
• variable density, air pockets, and hybrid fill strategies for comfort
• polar kinematics and toolpath planning as the next frontier
• print farms, software orchestration, and scaling production

Special thanks to Advanced 3D for sponsoring this episode.

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We talk with Molly McCoy about turning dense policy into practical tools, writing notes that get covered, and why advocating coverage can improve outcomes. The focus stays on patient stories, shared decisions, and using the whole medical record to support care.

• how clinician notes function as medical records and drive coverage
• writing people-first justifications that explain medical necessity
• using therapists’ and nurses’ notes to support decisions
• drafting notes in real time to capture shared decision-making
• where AI helps as a writing partner and where it harms
• working with payers while advocating for policy change
• why two devices enable both ADLs and true physical activity
• reducing burnout through smarter workflows and legislation
• telehealth access gains and state-level advocacy
• flexible roles, job sharing, and retaining clinicians in O&P

Special thanks to Advanced 3D for sponsoring this episode.

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Is this the lost episode? No, but there is some "old news".

We dig into how O&P is changing fast: major acquisitions, new L codes, and a fresh vision for education that blends clinical reality with digital tools. Adrienne Hill shares a grounded path for students and clinicians to build skills without burning out.

• Hanger’s acquisition of Point Designs and upper limb strategy
• Medicare L codes momentum for partial hand coverage
• Three education models and how to choose
• Why residencies still define clinical growth
• Embedding scanning, CAD, and 3D printing in coursework
• Practical literacy vs making the "sausage" in-house
• Shifts from plaster to digital and what’s realistic
• Workflows that prevent burnout and improve retention
• Ownership dreams, debt realities, and timing
• The modified seven-year rule for career moves
• How to pick residencies that fit your EQ and IQ
• Going rural or high volume to accelerate learning
• Broadening applicant pipelines and faculty needs

If you need any help with additive manufacturing reach out to our sponsor, Advanced 3D.

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