steptics: efficient and affordable manufacturing of sustainable foot prostheses

Manufacturing high-quality foot prostheses from carbon or fiberglass is a complex and cost-intensive process. The founders of the start-up steptics have developed a method that automates this process. In doing so, they also rely on modern AI solutions with sustainability in mind.

In this interview with MEDICA-tradefair.com, Marc-Antonio Padilla and Daniel Kun talk about the manufacturing process of their start-up, the further development of the technology and who could particularly benefit from it.

What challenges does steptics face?

steptics: In the beginning, we at steptics specialized in sports prostheses. It is not easy for amputees to get back into sports. This is also because the corresponding prostheses are not covered by health insurance. Our goal is to provide cost-effective, high-performance sports prostheses. To this end, we have developed a process that automates many manufacturing steps.

How does the automated manufacturing process for steptics foot prostheses differ from conventional manufacturing methods?

steptics: Normally, springs are manufactured by hand, layer by layer. Be it carbon, fiberglass or an alternative fiber. We, on the other hand, use a winding process that already exists in this form, but has never been used in the production of prostheses. Here, the fiber is first drawn through an epoxy resin and then wound onto a rotating tool.

After the material has cured, we cut it into individual pieces. These pieces are then cut in half again. In this way, we have several blanks relatively quickly and extremely efficiently. These blanks are then individually cut to fit the wearers.

How do you determine the appropriate parameters for fitting the prosthesis to people individually?

steptics: Here, too, we rely on technical assistance. We have developed an AI that calculates various constants. These include stiffness and energy transfer, for example. The prosthesis blank is cut and milled using these parameters. This is a crucial point for sports prostheses in particular, as they have to deliver higher performance than everyday prostheses.

Are there also innovative approaches as far as the material is concerned? Keyword CO2 footprint and sustainability.

steptics: The first steps were cost reduction through automated production of blanks and the development of AI for customization. Now we want to address the issue of sustainable materials. Carbon or fiberglass unfortunately do not have the ideal carbon footprint. However, not every natural fiber is suitable as a material for sports prostheses or even everyday prostheses either. Their strength is usually not sufficient to withstand the prevailing loads. We are still in the process of researching what type of fiber might be suitable for this purpose.

At what point in the development are you currently?

steptics: We are currently in the test phase. The first test subjects are being selected, and we will certainly make one or two adjustments based on this data. At the same time, we are getting certified as a medical technology manufacturer. This all takes time, but we expect to have the first product ready for the market in the first quarter of 2024.

And the long-term vision?

steptics: Sustainability is one issue. But availability in the global South is also a major concern for us. In places where there is a lot of demand but not enough purchasing power. Here, we want to offer appropriate solutions with our automated and efficient processes in order to ultimately make our prosthesis available to all people.