3D printing a bionic arm

Corey Symon is a trombone-playing 14-year old with a passion for the sport of fencing. He was also born without his right-hand and forearm. Now, thanks to Dunedin’s International Science Festival and US non-profit Limbitless Solutions, he is the proud owner of a 3D-printed bionic arm.

Corey Symon photo Alison Ballance

Corey Symon and Brendan Jones repairing the bionic arm photo Alison Ballance

A bionic arm from Limbitless Solutions photo Kt Crabb Photography

The evolution of the Iron Man bionic arm, from white 3D printed plastic to finished arm. Limbitless Solutions photo Kt Crabb Photography

Engineer Brendan Jones from Limbitless Solution restringing a finger in Corey's bionic arm. photo Alison Ballance

Corey practising the grip of his bionic hand. Limbitless Solutions photo Kt Crabb Photography

Volunteers making bionic arms Limbitless Solutions photo Kt Crabb Photography

Corey giving his mum Vanda a hug Limbitless Solutions photo Kt Crabb Photography

Annie with her Limbitless Solutions bionic arm. Each recipient decides how they want their arm decorated. Photo Kt Crabb Photography

Bionic kids with their Limbitless Solutions arms - to date 16 kids have been gifted arms. Photo Kt Crabb Photography

Alex riding a bike with his Iron Man bionic arm. Alex was the first kid to get a bionic arm from Limbitless Solutions. photo Kt Crabb Photography

Corey Symon with Limbitless Solution co-founders Albert and Katie Manero photo Alison Ballance

Limbitless Solution was set up by Albert Manero two years ago, when he realised there was a need for cheap prosthetic arms for kids who were missing all or part of their arm. He decided that open source software and 3D printing was a way to produce a robust arm that could then be fitted with electronics, powered by a rechargeable battery.

A bionic arm begins life as 3D printed plastic that then receives a custom paint job, before being fitted with its electronics. This is the Iron Man arm made for Alex. Photo: Limbitless Solutions / Kt Crabb Photography

The arms are decorated to match the personality of the recipient – the first arm that Limbitless Solution built and gifted went to Alex, a boy with a love of the robotic character Iron Man. Corey’s arm is sleek and grey, modelled on a sports car’s racing lines.

It takes about 30 hours to 3D print a bionic arm, and costs about US$330 in material, says engineer Brendan Jones, who has been in New Zealand to help fit (and fix) Corey’s new arm.

Corey has had prosthetic arms before, but they have had limited movement, relying on him flexing his whole arm to make the thumb open and close.

Corey Symon (left) and Limbitless Solution engineer Brendon Jones fix a damaged finger on Corey's bionic arm. The arms are designed to be easily repairable. Photo: RNZ / Alison Ballance

His new arm has a fully opening and closing hand. Corey wears three electrodes that are glued to his stump, and small electric signals produced as he contracts and relaxes his muscles are enough to open and then close the hand.

Albert is an aerospace engineering student, and Limbitless Solution relies on donations and volunteers to make each arm.

You can hear Albert in conversation with Jesse Mulligan here.

Corey Symon gives his mother Vanda a bionic hug. Photo: Limbitless Solutions / Kt Crabb Photography

Corey Symon - with his new bionic arm, and non-profilt Limbitless Solution founder Albert Manero and photographer Katie Manero Photo: RNZ / Alison Ballance