Atlanta VAHCS Pioneers 3D-Printed Medical Devices for Veteran Care

Utilizing the innovative ActivArmor system, the Atlanta VAHCS is now producing customized, waterproof, and breathable orthopedic devices for Veterans, with benefits for Orthopedics, the Emergency Room, Occupational and Physical Therapy, Podiatry, and diabetic clinics.

The ActivArmor system was acquired through a special collaborative contract with the Defense Health Agency (DHA) as part of a joint pilot program between the Department of Defense (DoD) and the Department of Veterans Affairs (VA). The initiative aims to evaluate the effectiveness of additive manufacturing for various medical needs.

The new technology addresses many common frustrations associated with traditional casts. Unlike plaster or fiberglass, ActivArmor devices can be worn in the shower or while swimming and are compatible with radiology scans. This eliminates "cast claustrophobia," reduces skin conditions related to traditional casts, and allows providers to visually monitor incisions and wounds as they heal.

ActivArmor devices are custom fit to each patient's anatomy using a 3D scan captured with an iPhone. Veterans can also personalize their cast with their choice of material color and decals. The technology allows for special adjustments to accommodate boney protrusions, Charcot foot ulcers, and bone and muscle stimulators.

The 3D printing project is spearheaded by Mr. Austin Samuelson and Mr. Gregory Doss from the Atlanta VA's Healthcare Technology Management Service Line. The initiative was assigned to them by the facility director as part of their facility-level VISN 7 VALUE LEAD project. The final 3D-printed devices are produced and finished in the Joseph M. Cleland Atlanta VA Medical Center prosthetics lab.

Mr. Doss expressed his pride in the program, stating, "Bringing this cutting-edge technology to our Veterans is a game-changer. We are not only providing a more comfortable and hygienic alternative to traditional casts but are also empowering Veterans with a personalized device that fits their lifestyle."

By bringing this technology in-house, Atlanta VAHCS aims to reduce wait times for patients and significantly cut costs. The system can print everything from standard wrist, hand, thumb, ankle, and foot splints and casts to full-length casts for legs and arms. Print times vary from 3 hours to overnight, depending on the complexity of the device.

“Innovation that directly enhances the lives of Veterans is central to our mission at the Atlanta VA Health Care System,” said Atlanta VAHCS  Executive Director Kai D. Mentzer.  "Through the introduction of 3D-printed medical devices, we’re not only improving comfort and recovery for our Veterans, but also advancing the quality, efficiency, and personalization of their care. This effort reflects our unwavering commitment to bring cutting-edge solutions to those who have served our nation.”

Healthcare providers across the clinical areas involved can order ActivArmor devices by placing a consult order into the Computerized Patient Record System (CPRS). Veterans needing this service must come to the Joseph M. Cleland Atlanta VA Medical Center for the required 3D scan.

“The success of this initiative showcases what’s possible when technology, teamwork, and dedication to Veterans come together, "said Fred Brevard, Supervisory Health System Specialist to the Executive Director and Atlanta VAHCS’s ILEAD Executive Champion. "The Atlanta VA Health Care System is proud to lead this effort, setting a new benchmark for innovation in Veteran care. Every advancement like this strengthens our ability to deliver the exceptional, personalized service Veterans deserve.” 

Looking ahead, the facility plans to expand its 3D printing capabilities beyond the initial two ActivArmor systems to include orthotic inserts and prosthesis check sockets for amputee patients.