3D Printing

Printing play: A path forward for children with prosthetics

Nathan Kahl — Thu, 15 Jan 2026 13:32:50 +0000

Printing play: A path forward for children with prosthetics Nathan Kahl Thu, 01/15/2026 - 08:32

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A child who uses a lower-limb prosthesis faces unique challenges when it comes to activities most children take for granted, such as running and being active. Without access to a prosthetic device designed to support these movements, children may miss out not only on the simple joys of play, but also on critical opportunities for physical development during key stages of growth.

Quentin Sanders. Photo by Ron Aira/Office of University Branding

�鶹��Ƶ researcher Quentin Sanders is part of a collaborative research team working to make high-performance prosthetic limbs more affordable, accessible, and better tailored to the needs of active children. Sanders, along with Jonathon Schofield, an associate professor at the University of California, Davis, and Garrett Melenka, an associate professor at York University, received a three-year, $500K grant from the National Science Foundation to support the project, which began in September 2025.

Most standard foot or leg prostheses are built for basic walking, not for the kind of active movement that helps children develop strength, balance, and coordination, the benefits that come from running and jumping with friends.

“This limitation can be especially challenging for children,” said Sanders, who has a joint appointment in the Department of Bioengineering and the Department of Mechanical Engineering. “Kids want to run and play. When they can’t, they’re more likely to avoid physical activities, such as sports, or even stop using their prosthesis altogether.”

A 3D-printed running blade prototype, created using the technique Sanders and his colleagues are developing. Photo provided

Often seen in competitive events such as the Paralympic Games, running blades are curved, spring-like prosthetic feet made from carbon fiber that mimic the energy return of a biological foot. While these devices offer an alternative option to standard leg prostheses and can enable children to run, they are expensive and often inaccessible. A single running blade can cost several thousand to tens of thousands of dollars and is typically not covered by insurance because it is considered nonessential, rather than medically necessary.

Some charitable organizations help families access these devices, but demand far exceeds supply, and for growing children, one blade is rarely enough. “Kids grow quickly,” said Sanders. “As they get taller, they outgrow their prostheses, which means going through multiple blades over time.”

The research team has several goals, starting with identifying what children truly need from an activity-enabling prosthesis. The researchers are examining how motivation to be active, physical growth, and different types of movement influence prosthetic performance in everyday settings. “What do you use it for? What don’t you use it for? What do you wish you could do?” said Sanders.

The team is also analyzing how children move while using their current running blades, studying activities such as running, jumping, and changing direction to better understand the biomechanics and physical demands involved.

Finally, the team will take a close look at how today’s running blades perform under real-world demands. “We want to understand how stiff they are, how much load they can handle, and when they might fail,” said Sanders. “We can then combine that information with what kids tell us they want to do and use it to guide our 3D printing process—creating blades that are better suited for active play.”

Sanders and his collaborators are using an advanced additive manufacturing approach known as continuous-fiber 3D printing, in which carbon fibers are embedded within the printed plastic to reinforce the prosthetic structure. This method enables the creation of strong, lightweight devices that can be tailored to a child’s size, growth, and activity needs.

“By combining manufacturing, composite materials, prosthetics, design, and biomechanics, this project provides an innovative and holistic solution,” said Melenka.

The technique is already used to produce strong, lightweight components in the aerospace and automotive industries, but it has seen limited adoption in prosthetic design. This project represents one of the first efforts to apply it systematically to activity-enabling prostheses for children.

“What’s most exciting about this project is the collaboration across institutes, disciplines, and areas of expertise,” said Schofield. “We are bringing together researchers in movement mechanics, advanced materials manufacturing, and pediatric lower-limb prosthetic care. We are also incorporating the lived experience of children and families, along with clinicians who work with these patients every day.”

The work also has the potential for industry disruption, according to Sanders. “If we can show that a child’s physical measurements and movement needs can be translated into a digital model and then used to 3D print a customized prosthesis, existing prosthetic manufacturers would begin to integrate this approach into their production pipelines.”

For Sanders, the motivation goes beyond technical innovation. “I’ve always been interested in translating new technologies into real-world solutions,” he said. “Helping people with disabilities and impairments is why I got into this field in the first place.”

Topics

Bioengineering

mechanical engineering

3D Printing

Research

National Science Foundation

Fuse at �鶹��Ƶ Square

GCI-Health

Working on spacecraft and 3D-printed solar cars, junior accelerates his career at �鶹��Ƶ

Mariam Aburdeineh — Tue, 25 Jan 2022 19:15:24 +0000

Working on spacecraft and 3D-printed solar cars, junior accelerates his career at �鶹��Ƶ Mariam Aburdeineh Tue, 01/25/2022 - 14:15

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John Shortle

Syed Abbas Zaidi

Michael Riggi, president of �鶹��Ƶ's solar car team, Hypernova Solar, poses with Orion, a solar car his team revamped. Photo provided by Hypernova Solar.

Since Michael Riggi was about six years old, his father and brother would take him to a “Cars and Coffee” show in Great Falls, Virginia, on weekends. Being around classic automobiles and luxury vehicles, Riggi said he developed an appreciation for cars, and other machines that go fast, including planes, boats, and rockets.

Riggi developed an appreciation for cars at a young age. Portrait by Michael Riggi.

Now, as a junior at �鶹��Ƶ, his career path has also been racing forward.

The systems engineering major working on an accelerated master’s degree is the president of Hypernova Solar, a student organization creating what they believe will be the world’s first 3D-printed solar car.

Ultimately, Riggi said he aspires to work in the aerospace industry. His work with Hypernova Solar combined with his degree helped him land an internship with the global aerospace, defense, and security company, Northrop Grumman, he said.

“[Systems engineering] is in high demand in almost all tech industries,” Riggi said.

“�鶹��Ƶ is one of the only schools I found in this area that offered a system engineering major, and �鶹��Ƶ’s program was ranked higher than [the University of Virginia]’s,” he said. “I chose �鶹��Ƶ off their great program.”

When Riggi interned with Northrop Grumman in summer 2021, he said he worked on spacecraft that go up to the international space station—in particular, the Cygnus Mission. Riggi said his tasks involved taking measurements, estimating error, and creating a CAD model of the thruster.

Riggi interning at Northrop Grumman. Photo provided.

“We made a tool that allowed Mission Control to quickly throw in measurements of the motors to see how it affects the angle of the spacecraft on-the-fly, so they can steer the spacecraft,” Riggi said.

“The qualities about Michael that impressed me and my colleagues [at Northrop Grumman] were his imagination and ability to tackle a task that was initially beyond the scope of his previous experience,” said Roseann Alvarez, systems engineering manager at Northrop Grumman. “He shows plenty of growth potential and will be an asset to any future employer.”

“Based on Michael’s performance and his contributions to the [Commercial Resupply Services] program, I would highly recommend Northrop Grumman recruitment of �鶹��Ƶ interns and graduates in the future,” she said.

Riggi said he’s excited to intern again with Northrop Grumman in summer 2022.

“There’s something about being on the cutting edge of technology and science that I really love,” he said. “[My internship] helped me realize what traits I value in a workplace and helped me realize specific parts of my education to focus on because I’ve seen what’s actually needed in the workforce.”

In addition to opportunities in the Washington, D.C., metropolitan area, Riggi said he has enjoyed learning from supportive �鶹��Ƶ professors including John Shortle, Abbas Zaidi, and Colin Reagle.

“Michael embodies the ideal of a systems engineer, being able to assemble and lead a large team of students with diverse skills to design, build, and test a complex system,” Shortle said. “He’s a great ambassador for the discipline and will be a great asset in the workforce.”

When he’s not leading Hypernova Solar, Riggi said he enjoys going off-roading and taking photos.

When he's not leading Hypernova Solar, �鶹��Ƶ student Michael Riggi enjoys going off-roading with his truck and taking photos. Photo by Michael Riggi.

Photography by Michael Riggi.

“It’s really a great way to blow off steam and relax,” Riggi said, suggesting diverse activities help keep his life balanced yet exciting. “If there’s one thing I hate, it’s being bored.”

That’s another reason he appreciates the opportunities at �鶹��Ƶ.

“My favorite part of �鶹��Ƶ is the community,” Riggi said. “The diverse student population has taught me so much and helped me make so many friends, the amazing faculty have been so helpful, and the community of Fairfax is very diverse and a great space to explore.”

Riggi (front left in green) with members of �鶹��Ƶ's solar car team, Hypernova Solar. Photo by Shelby Burgess/Strategic Communications/�鶹��Ƶ

Topics

Systems Engineering and Operations Research

Space

space exploration

experiential learning

accelerated masters

diversity

Racing toward �鶹��Ƶ’s first 3D-printed solar car

Mariam Aburdeineh — Wed, 17 Nov 2021 17:50:29 +0000

Racing toward �鶹��Ƶ’s first 3D-printed solar car Mariam Aburdeineh Wed, 11/17/2021 - 12:50

In This Story

Hypernova Solar, �鶹��Ƶ's student-run solar car team, meets at the MIX to discuss progress and moving forward with building a 3D-printed, solar-powered car for competition. The team is building the 3D printer, pictured here, that will be used to build the car. From left to right: �鶹��Ƶ undergraduates Abigail Kennedy, Phoenix Lee, Brandon Escobar, Kareem Elsharkawy, Petr Soucek. Photo by Shelby Burgess/Strategic Communications/�鶹��Ƶ.

Most people with access to a 3D printer find themselves creating small objects or gadgets. But one student group working at the MIX at �鶹��Ƶ each Friday is driven by a different dream.

“We build, design, test and plan to compete in solar-powered car competitions,” said Michael Riggi, president of �鶹��Ƶ’s solar car team, Hypernova Solar. “[We believe] our car, when complete, will be the world’s first and only 3D-printed solar car.”

Riggi, a junior studying systems engineering, said the team aspires to compete in the American Solar Challenge, which involves racing a couple thousand miles across the country against other university teams. Their subsequent goal is to race in the World Solar Challenge in Australia.

When Hypernova Solar was founded in 2019 by �鶹��Ƶ alum Alex Hughes (BS Bioengineering, Honors College '21), Riggi said the group laid the logistical groundwork for parts, designs, and fundraising. Today, the group’s 50 members comprise everyone from �鶹��Ƶ freshmen to seniors, and a few students from Northern Virginia Community College (NVCC) and local high schools.

Their momentum has been strong.

“We’re in the process of building our own car, Hypernova One, that we plan to complete in about a year,” Riggi said, adding that the car’s steel frame that they weld on �鶹��Ƶ’s Science and Technology Campus is halfway done.

From left to right: Johnnie Hall (ME Lab Shop Technician, Volgenau School) and mechanical engineering major Abigail Kennedy welding the new suspension for Orion in May 2021. Photo by Michael Riggi.

From left to right: Johnnie Hall, Exploratory Honors College student and EIP alum Elyas Shafiq, and Environmental Science major Brandon Escobar welding Hypernova One's frame in October 2021. Photo provided by Hypernova Solar.

Hypernova One will be the team’s proof-of-concept car, he said. Once it’s complete, they’ll review it to see what could be done better, and then build a second car for competition.

The group has also been working on a car that was donated to them in 2020 from the University of California, Berkeley team.

“We’ve completely revamped the suspension, the motors, the aeroshell and repainted it,” Riggi said of the 10-year-old vehicle they renamed Orion. “It gave everyone a good experience on what actually goes into a solar car.”

Michael Riggi, president of Hypernova Solar, with Orion. Photo provided by Hypernova Solar.

They’ve also been benefiting from �鶹��Ƶ’s resources and experts.

“My systems engineering coursework has helped me manage the team, understand business concepts, as well as understand the engineering aspects and challenges presented to us,” Riggi said. “I’ve also taken a MIX workshop on 3D printing and am applying this knowledge to building a 3D belt printer to create the shell of our first car.”

A model of Hypernova One's shell. Image provided by Hypernova Solar.

Why is the team developing their own 3D printer?

“Unlike a 3D printer where you’re printing layer by layer going up, ours is tilted at a 45-degree angle and prints on a conveyor belt, so you can actually print on an unlimited axis,” said Ross Clark, Hypernova Solar’s lead designer and a NVCC student who said he’s transferring to �鶹��Ƶ.

The unique printer helps make the car resilient and safe, he said. Printing vertically would make it more susceptible to breaking along the X-axis.

“The shell is going to be sturdy and meet safety regulations,” Clark said. “We’re also using a special plastic, PETG, which doesn’t break, it flexes more, and is a lot more heat resistant.”

“I’ve been impressed by the team’s passion and drive,” said faculty advisor Colin Reagle. “They are constantly pushing boundaries on what they can do within a university setting.”

“The opportunity to build a unique machine like this is a huge draw to a diverse group of students,” said Reagle, who teaches in the Department of Mechanical Engineering. “I can’t wait until you see them rolling around campus in this vehicle inspiring the next surge of students.”

Exploratory student Kareem Elsharkawy drills holes in aluminum at the MIX to help create a 3D belt printer, November 2021. Photo by Shelby Burgess/Strategic Communications/�鶹��Ƶ.

Overall, Hypernova Solar is about more than just building cars.

“The most rewarding part is seeing progress on the car and watching team members develop new skills,” Riggi said. “Our goal is to develop the skills of the students, make them more well-prepared for the workforce, and also just make friends.”

In addition to the thrill of problem solving, and the joy of mentoring new members, Clark and Riggi said another benefit is the group’s inclusivity.

“We have a spot for everyone—even if you’re not an engineering major,” Riggi said. “Some members aren’t huge car people, but want to develop personal skills, or do business and fundraising.”

“That’s why I love this project so much,” he said, “you can tailor it to what you want to get out of it.”

Hypernova Solar, �鶹��Ƶ's student-run solar car team, meets at the MIX in November 2021. Photo by Shelby Burgess/Strategic Communications/�鶹��Ƶ.