KU Engineers Create Innovative Prosthetic Manufacturing System

Innovating Healthcare Solutions in Nepal

In the heart of Kathmandu, the Spinal Injury Rehabilitation Centre houses a unique space known as the wheelchair graveyard room. This room is filled with hundreds of wheelchairs that once provided mobility to patients but now sit broken and unusable. Most of these wheelchairs were donated from various parts of the world, and due to their different brands and models, even minor damages render them irreparable.

To address this issue, researchers at the Design Lab, a mechanical engineering lab based at Kathmandu University, are working on producing essential medical devices locally for patients with disabilities. Their goal is to make these devices more affordable and tailored to the specific needs of Nepali patients.

Localising Medical Device Manufacturing

Led by Assistant Professor Pratisthit Lal Shrestha, the Design Lab was established in 2019 to create a space where engineers can bring their ideas to life. The lab has since grown significantly, equipped with a range of advanced tools including 3D printers, scanners, and other manufacturing equipment. The powder-based 3D printer, which offers the highest level of accuracy, is the only one of its kind in Nepal.

The Design Lab collaborates with the KU School of Medical Science and other medical experts to ensure that their innovations meet the real-world needs of patients. One of their key projects involves creating more affordable and effective prosthetic devices for children.

Addressing the Needs of Children with Disabilities

Children who use prosthetic legs often need to switch to a larger prosthetic twice a year. Most opt for the cheapest option, which features single-access knee joints. However, these joints remain rigid when standing, making walking difficult. To solve this, the Design Lab developed polycentric knee joints using 3D printing technology, reducing the cost from Rs50,000 to around Rs20,000. If production scales up, they believe they could cut costs by five times.

The lab has also created a prosthetic foot that allows for natural toe movement, improving the gait of users. A patient who lost his foot due to diabetes-related nerve damage found the prosthetic so comfortable that he started wearing it full time.

Expanding the Scope of Innovation

Beyond prosthetics, the Design Lab is involved in various other projects. They are working on improving the durability of silicon prosthetic liners, experimenting with electromyographic sensors for functional prosthetic hands, and developing devices like cryotherapy machines and halo braces for stroke survivors and post-surgery patients.

The potential impact of their work is significant, especially in a country where access to assistive technologies is limited. According to the 2021 census, 240,609 people in Nepal live with physical disabilities. While 64% of people in high-income countries have access to such devices, only 11% in low-income countries do.

Tailoring Devices to Local Needs

Localizing production not only reduces costs but also allows for customization to suit local conditions. For example, imported prosthetic knees may not be designed for sitting on the floor, which is a common activity in many households. By focusing on local needs, the Design Lab ensures that their devices are practical and user-friendly.

Dr. Shrestha envisions launching a healthcare technology research and innovation centre as a spin-off of the Design Lab. This initiative aims to further expand the scope of medical device innovation in Nepal.

Inspiring Future Innovators

The success of the Design Lab has inspired a new generation of innovators. Former students have launched startups like Nyanocare, NeplaFil, and ReGen Nepal, all of which began at the lab. These companies focus on 3D printing, filament production, and converting plastic waste into furniture materials.

For current students, the opportunity to work on real-world projects while studying is invaluable. Third-year bachelor's student Dilasha Adhikari expressed her gratitude for being part of the Design Lab, highlighting the learning opportunities it provides. Similarly, Arya Ghimire emphasized the importance of creating devices that are both cost-effective and efficient.

The dedication of the Design Lab team continues to drive innovation in Nepal, offering hope and better quality of life to those with disabilities. Through their efforts, they are not only addressing immediate needs but also laying the foundation for a future where healthcare solutions are accessible, affordable, and tailored to local requirements.