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A Hospital 3D Prints to Practice Medicine

cincinnati-childrens-hospital-makerbot-birthmark

A few days after my post about innovative patients using desktop 3D printing to help themselves and their loved ones, I visited Cincinnati Children’s Hospital, where I met Matt Batie, a clinical engineer and a true inspiration. Batie uses two MakerBot Replicator Z18s to prepare surgical teams for complex operations.

When I was there, he was working on a case involving a child who has a birthmark covering much of his torso. Many birthmarks need to be removed, since they can develop into skin cancer. To get rid of a large birthmark, a plastic surgeon will implant tissue expanders — basically medical-grade water balloons — under the child’s skin. Over the course of a few months, the balloons will fill with fluid and skin will grow and stretch over them. When enough healthy skin grows, the birthmark can be removed and the healthy skin can cover where it was.

To plan for this kind of operation, the surgical team will practice on 3D prints of the the torso (or whatever part of the body is affected), which Batie makes from a scan on the MakerBot Replicator Z18. Following instructions from the plastic surgeon, he will make a model that incorporates the fully ballooned expanders into the torso, then cover it with skin-like rubber just like Hollywood special-effects artists use. This way, surgeons can test whether they’ve found the best places to implant the expanders, and also the best places to cut when they’re ready to remove the birthmark. After trying out various approaches and choosing the best one, they can also generate a precise template that will guide their incisions during an operation.

Cincinnati Children’s Hospital has used this technique already with five children, including a toddler named Lily, who had birthmarks on her face, head, and neck. Surgical planning on a 3D print can help surgeons reduce operating time and avoid errors — so it improves a child’s chances for success. Thomas Sitzman, the plastic surgeon who treated Lily, has said, “I think being able to model each individual patient’s surgery in advance is going to just bring us a tremendous step forward.”

Other hospitals are also using desktop 3D printers to plan delicate operations. In Louisville, Kosair Children’s Hospital made a 3D model of a 14-month-old boy’s heart before repairing a hole in it. “Once I had a model of this child’s heart, I knew almost exactly what I needed to do and how I could do it,” Dr. Erle Austin, III, said at the time. Houston Methodist Hospital printed a full-scale model of the brain of a 37-year-old man before removing a malignant tumor. Veterinary surgeons are also using MakerBot to generate models of patients and reduce operating time and risk.

After ten years in the 3D printing business, you can still meet amazing individuals who are using this technology in ways you never thought possible. And as Matt Batie and his colleagues at Cincinnati Children’s Hospital told me, “This is only the beginning.”

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Innovative Patients Help Themselves

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A missed connecting flight in Chicago meant that the Arkansas leg of my 11-week, 22-state Listening Tour was unfortunately restricted to listening. I called in to a meeting with the EAST Initiative, which provides students with 3D printers and other technology to learn through projects that serve their communities.

And at the Innovation Hub, a makerspace in North Little Rock, I missed meeting Mike Kelley, a member who came by to use the MakerBot Replicator Z18 to take care of himself.

Kelley has a denegerative spinal disorder. He was at the Innovation Hub that morning to print a 3D model of his cervical spine, the section just below the neck. He started with a recent CT scan, which takes a lot of two-dimensional pictures, and found free software online that converts those slices into a 3D printable file. A network engineer at Cisco, Kelley had never used a 3D printer before, but he likes to make things in his shop at home, and he quickly got a handle on the MakerBot 3D Ecosystem and created a replica of his upper spine.

Kelley plans to bring the model of his spine to his next doctor’s appointment. In the meantime, friends can now see how his bones are worn down, and they seem to understand better that he’s hurting. “For a guy that will be 52 later this month, I think I’m very healthy,” says Kelley, who is a competitive weightlifter. “People don’t realize that sometimes I’m just sucking it up and getting through the day.”

The model also has helped Kelley come to grips with his own condition. He considers himself a visual person, and he had trouble deciphering the CT scan. 3D printing, he says, “brings back that mechanical approach to things.” Doctors have more practice reading CT scans, but 3D printed models are more clear, and can lead to better informed decisions.

Kelley is one of many people who have found their way to desktop 3D printing to manage their own medical problems or those of their loved ones. After 6-week-old Ari needed an emergency operation on her walnut-sized heart, her mother, Anne Garcia, started a nonprofit called OpHeart so that planning with 3D printed heart models becomes the standard for surgery on young children. When Michael Balzer’s wife needed a brain tumor removed, he printed a model of her skull and sent it to her surgeon, who was then able to perform a less invasive surgery. A Hodgkin’s patient printed out models of his tumor when it was discovered, and again after radiation and chemotherapy made it shrink. Researchers are modifying the MakerBot Replicator 2X Experimental 3D Printer to look into custom treatments, from administering the right amount of medication to replacing sections of windpipe. And of course there is Robohand, which began as a way to help one man and has grown into a global effort to provide low-cost prosthetics.

When it comes to 3D printing, doctors can get good ideas from patients, just as teachers can learn a lot from their students. Kelley says he told some doctor friends about his spine model, and they now want to know how he made it. Desktop 3D printing can make the worrisome world of medicine more concrete and accessible, and break down barriers between doctors and patients.

The same user-centered principle is behind the Bay Area Makeathon for Assistive Technology. We are proud to be the 3D printing partner for the event, which is hosted by TOM, UCP of the North Bay, and Google.org. At the Makeathon, people with skills such as product design, coding, and 3D printing will be collaborating with people who understand the needs of people with disabilities, including the people with disabilities themselves. We invited Kelley to join us at the Bay Area Makeathon, and he will use his making skills — including perhaps his newfound knowledge of 3D printing — to help others.

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A Fixture on the Production Line

MakerBot CEO Jonathan Jaglom and productor Wilson Feliciano

MakerBot CEO Jonathan Jaglom and productor Wilson Feliciano

MakerBot has a 3D Ecosystem that helps others — engineers, designers, educators, students, hobbyists — to turn their ideas into reality. It includes software, materials, and support, but these elements of the MakerBot 3D Ecosystem all involve the 3D printers that we make in Brooklyn — now in a new factory, with double the manufacturing capacity.

A few days after we opened the factory, I spent a few hours on our production line, as part of the human ecosystem that is ramping up the factory to full capacity. I worked a station on the MakerBot Replicator 2X line, building what we call the Z stage: the motor, the threaded rod, the holder that heats the build plate. At the Z stage station, as at many work stations, the task of assembly involves a fixture to hold the parts in place. Fixtures can be machined, but 3D printed fixtures take less time and money to make than metal ones, and in many cases are just as good as metal. 3D printed fixtures allow us not only to create a repeatable manufacturing process, but to refine and improve the process as we go.

You might expect us to make our own fixtures on MakerBot Replicators, but we’re not alone. In Chicago a couple of weeks ago, on my 11-week, 22-state Listening Tour, I stopped by the Center for Lost Arts, monthlong pop-up community workshop, where the makers of the Beton Coffee Storage Vessel were making rewards for their backers on Kickstarter. They had 3D printed a fixture to shape the handle of the coffee scoop using the MakerBot Starter Lab at the Center for Lost Arts.

Beton is a two-person operation — Dan Cigler and Travis Koss — but the big boys do it, too. I went to see a multibillion-dollar manufacturer with a million-square-foot facility, and they make some fixtures on a MakerBot Replicator Z18.

The Z stage fixture back at our factory worked pretty well, but if I’d had any ideas, I could have shared them with our manufacturing engineers and, in a matter of hours, we could design and 3D print something new and see if it made things go more smoothly. And that’s not just because I’m the CEO: Any worker on the line can recommend an improvement to the workflow, which can be tested with a small investment of time and filament, and if it’s not right the first time, we can try again. The worker shapes a process he or she understands best; the line becomes more productive. Everybody wins.

Soon there will be customers who will have a MakerBot Replicator 2X that I helped to assemble, and it means a lot to be able to take pride in our products in this direct, physical way.

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A 3D Printer on the Desk of Every Engineer and Designer

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At the center of the MakerBot Replicator Desktop 3D Printer — our best known product — is the word “desktop.” I now think a lot about the tops of desks, after a decade around industrial 3D printers. And I believe that the desk of every engineer and every designer needs a 3D printer on it. That’s true whether you work in a one-person studio or a Fortune 500 company.

Of course mass adoption would be great for MakerBot. But I firmly believe that a 3D printer on every engineer’s and designer’s desk is what every company needs, that being so close to a 3D printer makes a quantum difference in your ability to create and innovate, to make your best work.

Desktop isn’t just about size. As I headed last week to Chicago and up into Wisconsin to meet with GE Healthcare, S.C. Johnson & Son, and other customers on my Listening Tour, I got new insight into how engineers feel when they are making things and solving problems. One engineering manager told me he has noticed that engineers will try out riskier stuff — more daring concept models, multiple options — when they have a 3D printer on their own desk, ideas that they’d be too embarrassed or intimidated to send to the internal print service bureau, lest somebody see and judge them before the ideas have been worked through. “I have seen product development ideas that were not possible before, simply by having the printers sitting beside the engineers,” he said.

Back in New York, Mark Palmer, MakerBot’s director of industrial design, affirmed the engineer insight. Before MakerBot, Palmer worked for Motorola Solutions in New York. His “rapid prototyping” involved ordering 3D prints from Motorola’s internal prototyping labs, on site and in Florida. It wasn’t just the queue time and distances that added friction to the process, but the inevitable second-guessing by other designers, engineers, and business leaders who would see your prototypes in the lab, waiting to be picked up. Without proper context, an early prototype could be viewed as a failure, or it might be politically volatile.

Some prototypes need to be kept close to the chest until the time is right. Think of what you’d write in a notebook but not on a whiteboard, or on a whiteboard but not post on the company Intranet.

Prices can also affect how you prototype. Filament for a desktop 3D printer costs a lot less than materials for an industrial one — so much less that, for some companies that own a bigger 3D printer, the savings on materials alone will pay for a new MakerBot Replicator. Likewise, if you’ve ever ordered SLAs from a vendor, a desktop 3D printer can cost less than a couple of those. The relatively small cost of desktop 3D printing materials leads to more and bolder experimentation.

Then there are feedback loops, which are much quicker with a 3D printer on your desk. One engineer told a story about how he can look at a print that’s only half done and already see what needs more work. He hits cancel, reworks his 3D design file, and starts printing on his MakerBot Replicator again. More iterations, more refinement, means better solutions.

There will be skeptics, just as there were when the office computer was a mainframe that took up most of a room and the PC showed up. A 3D printer on every desktop isn’t some far-off dream. It can happen now.

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Opening Our New, Bigger Brooklyn Factory

L-R: Dan Freedman, SUNY New Paltz; Randy Asher, Brooklyn Tech H.S.; Jonathan Jaglom, MakerBot; Eric Adams, Brooklyn Borough President; Mathew Mandery, Brooklyn Tech Alumni Foundation; Ryan Grepper, Coolest

L-R: Dan Freedman, SUNY New Paltz; Randy Asher, Brooklyn Tech H.S.; Jonathan Jaglom, MakerBot; Eric Adams, Brooklyn Borough President; Mathew Mandery, Brooklyn Tech Alumni Foundation; Ryan Grepper, Coolest

MakerBot opened its new, 170,000-square-foot factory this morning in Industry City, in Brooklyn, NY, ensuring that the phrase “Made in Brooklyn” will continue to be inscribed on the back of MakerBot Replicator 3D Printers for years to come.

“We are very proud that we are here in Brooklyn, not only in our services and design and marketing, but in our operations,” said Jonathan Jaglom, CEO of MakerBot, who told a crowd of more than 100 employees, educators, students, and government officials at Industry City, a manufacturing, shipping, and distribution center which at its peak employed 25,000 people. Jaglom could not contain his excitement that MakerBot was reinvigorating a manufacturing space in Brooklyn.

Neither could Brooklyn Borough President Eric Adams, who held up a 3D printed nut and bolt and quipped, “For many years folks in this community, instead of making screws, felt that they were being screwed.” Adams told the audience that half of employees in Brooklyn have at most an associate’s degree, and 47% of Brooklyn residents speak a language other than English at home. “When we train that workforce, we give them an opportunity to be a part of a technology that will move the entire globe. We want to be a part of that,” he said.

“We’re only as good as the people who come to work for us,” said Jaglom. He pointed to Diana Pincus, MakerBot’s vice president of operations. She joined MakerBot three years ago, when the factory was in a Gowanus garage and her desk was a plank on two sawhorses. Pincus oversaw the creation of the new factory, which streamlines production, doubles production capacity compared to MakerBot’s old Industry City facility, and follows principles of lean manufacturing, which emphasizes waste reduction and efficiency.

“Lean is a culture, not an activity, so we’re on a journey to making the MakerBot Factory a world-class manufacturing facility,” said Pincus, whose team uses its 3D printers to create the jigs and fixtures they depend on improve the productivity and quality of their work.

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Other speakers at the opening included Randy Asher, principal of Brooklyn Technical High School; Dan Freedman, dean of the school of science and engineering at the State University of New York at New Paltz; and Ryan Grepper, the inventor of the Coolest, a souped-up cooler which raised $13.2 million last summer on Kickstarter — at the time the largest amount ever raised in a crowdfunding campaign.

Grepper, who announced that Coolest would start shipping this week, spoke about how he prototyped his cooler using his MakerBot Replicator, and that 3D printing made it possible for him to test his ideas quickly and make improvements. “We live in an exciting time when anyone with the drive to learn how to use it can get access to a tool with this much power,” he said.

Freedman, who established the first MakerBot Innovation Center at New Paltz, concurred, calling 3D printers “the Swiss army knife of fabrication technologies.”

Guests then got a tour of the new factory, led by members of Pincus’ operations team.

Pincus — and MakerBot — are in a unique position. As she put it, “I consider myself very lucky to have built a factory not only in the United States, but in Brooklyn, my home.”

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The Vastness of It All

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When I became CEO of MakerBot just a hundred days ago, it was not just a new chapter for the company but a new chapter in my own life. I’ve been lucky enough to live in some great cities in Europe and Asia and travel the world for business, but I always wanted to come and live in the United States.

Already this is a dream fulfilled. As I look out the window of my office at MakerBot headquarters, I can see the Statue of Liberty standing in New York Harbor. At the end of the workday, I take the subway home to my apartment on the Upper West Side of Manhattan. The trains are filled with energy and carry an abundance of stories: An elderly woman dancing to her music, some guy sleeping in the most uncomfortable way imaginable, another couple making out obscenely. The smell of iron and the noise of chaos are somehow orchestrated into one enormous, unique experience.

These first 100 days at MakerBot have also been my first 100 days of calling America home, and the Listening Tour has been a trip of discovery. For trips to see customers and partners along the Northeast Corridor — Stanley Black & Decker, Staples, the University of Maryland —I start at Penn Station at dawn. I look up at the big board, waiting to find out where my train awaits me. The board is amazingly primitive but oddly charming. Less so when the conductor says, “We regret to inform you that we have stopped due to a train delay at the station ahead.” How come the birthplace of 3D printing — the most important technology of the 21st century —can’t figure out rail management? Japan prides itself on its shinkansen trains, which averaged a 36-second delay in 2012 between Tokyo and Osaka. Thirty-six seconds! But that thought fades as I take in the sheer beauty of nature along the ride and the variety of people traveling with me.

Boston…arrival. It all started around here not too long ago. The Rome of the Roman Empire, the Jerusalem of Judea, and the Babylon of Mesopotamia… Boston is for here (only its age has one digit fewer than the other cities). The “New” in New England resonates all around: the buildings, the narrow streets… As if in London (“but then again no” – “Your Song” with that English accent missing).

I can go on and on; alas, I need to put away Henry James and return to my business mind. But to all you folks out there reading, I want you to know that despite its challenges (and there are many), the United States remains the greatest nation ever built. A nation that has defined the free world as we know it, a nation that has helped liberate many from the horrors of evil, a nation that my ancestors and I personally owe a lot.

I look forward to exploring further — Illinois, Texas, California — and returning again to Brooklyn. I admire the vastness of it all.

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An Announcement

At MakerBot, we continue to evolve at an incredible pace. We’ve grown more than 600% from 2012 to 2014 – in short, we’ve grown incredibly fast.

As a company that’s focused on leading-edge innovation, we’ve learned to embrace change in order to stay focused.

Today, we at MakerBot are re-organizing our business in order to focus on what matters most to our customers. As part of this, we have implemented expense reductions, downsized our staff and closed our three MakerBot retail locations.

With these changes, we will focus our efforts on improving and iterating our products, growing our 3D ecosystem, shifting our retail focus to our national partners and expanding our efforts in the professional and education markets.

“These organizational moves are part of the continued scaling of MakerBot,” said David Reis, chief executive officer of Stratasys.

At MakerBot, we’re proud of being a highly innovative company that is leading the new product category of desktop 3D printing. We’ve experienced significant growth since inception, and achieved market leadership by iteratively testing, proving and pivoting our business.

We look forward to putting the power of desktop 3D printing in the hands of even more people in 2015.

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MakerBot | New Flexible and Streamlined Financing Options

Finance your next MakerBot purchase now!

Between MakerBot.com, MakerBot Retail Stores, and Certified MakerBot Resellers, there are already a lot of ways to get your hands on a MakerBot product. And now, thanks to our new financing partners, Affirm and LEAF Commercial Capital, there are two more.

A new consumer finance option for MakerBot customers
Affirm financing lets MakerBot customers split their payments into three, six, or twelve monthly installments. Affirm offers a quick and streamlined loan approval process built right into our order checkout. It’s a great way to buy your favorite MakerBot 3D printing and scanning devices and accessories without having to carry a balance on your credit card.

Benefits of financing with Affirm
– Easy Checkout: Get instant approval at check out from any device with just a few pieces of personal information.
– Flexible Financing: Grab your MakerBot products today and pay over time with a monthly payment plan that best fits your budget.
– Always Transparent: There are no catches or hidden fees, so what you see at checkout is exactly how much you will pay.

Take advantage of Affirm financing today at MakerBot.com. After adding your MakerBot product and accessories to your cart, select “Finance with Affirm” at checkout. Shop Now.

Shop MakerBot.com

Flexible financing for MakerBot business customers
Quickly prototype and build the next generation of commercial, industrial, and consumer products with MakerBot and LEAF Commercial Capital. With LEAF’s fast, easy, and flexible financing, acquiring the latest MakerBot 3D printing technology and services is simpler and more affordable than ever.

Benefits of financing with LEAF
– 100% Financing: LEAF can finance your entire MakerBot solution, including shipping, filament, and training.
– No Money Down: Get the MakerBot 3D printing technology you need with zero cash out of pocket.
– Flexible Terms: LEAF can customize payment terms to help businesses with seasonal variations and other changing business conditions.

Contact the MakerBot Sales Team to learn about flexible business and enterprise financing options through LEAF Commercial Capital, Inc., a recognized leader in equipment and software financing.

 

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Thingiverse | Countertop Challenge

3834 GE Challenge Banner_800 x 443px

Some people look at space and appreciate the emptiness; we look at space and see a blank canvas, awaiting inspiration. That’s where you come in.

We’re collaborating with FirstBuild to introduce the MakerBot Thingiverse FirstBuild Countertop Challenge. And we’re asking you to help fill in the empty space on your kitchen countertop.  The possibilities are endless.

To qualify, designs must be uploaded to both Thingiverse and FirstBuild.com between February 26th and March 14th, 2015, at 11:59 p.m. EST. Make sure to use the hashtag #CountertopChallenge. Winners will be announced on April 20th, 2015.

Make sure to read all the Official Rules here.

GO!

 

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Thingiverse | MakerBot Ghostly Vinyl Challenge Winners

Ghostly-Banner

Well that was awesome.

We had a feeling that this challenge was going to be right in the Thingiverse community’s wheelhouse and we were right!

For three weeks, Thingiverse was bombarded with hundreds of amazing #GhostlyVinyl Challenge entries ­— from customizable zoetropes, dancing ghosts and vinyl-based sculpture to clocks, wave generators, cable organizers, and so much more.

All participants deserve a round of applause for their hard work and creativity.

Picking finalists from all the inspired entries was tough, but after consulting with Ghostly International and recording artist Com Truise, we’re excited to announce the winners!

ChallengeWinners_Ghostly

And the winners are…

First prize goes to Oana’s Hand Cranked Vinyl Player. It prints without support and assembles in less than five minutes. It’s complex, but not complicated, and it can actually play records!

Second prize goes to M600’s DeskSHELL. It’s an elegant multi-purpose container for your audio miscellanea. It prints easily, looks perfect next to your turntable, and features some clever customizable elements.

Third prize goes to Aleccs’ Phone Amplifying Dock. The Ghostly-themed design holds an iPhone in place and redirects audio through an amplifying chamber.

UPDATE: Due to a judging error, we’ve changed the challenge winners. Check them out!

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Finance with Affirm

How does Affirm work?

Buy now with Affirm and pay over time. It’s simple financing that fits your life.

Monthly Payments

Pay over time with Affirm and split your purchase into 3, 6, or 12 monthly payments. Rates from 10-30% APR.

Easy Checkout

Select the Affirm payment option when you check out and provide some basic information to get instantly approved.

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