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Delft University of Technology

3D printing in Healthcare: A Practical Guide

Delft University of Technology via edX

Overview

This course is designed for healthcare professionals, biomedical technicians, clinical engineers and students in technical fields who are involved, or preparing to be, in the maintenance of medical equipment in low-resource healthcare settings.

In many hospitals and clinics, especially in low-resource settings, medical devices often become unusable due to the lack of affordable spare parts and there is often also a shortage of locally available assistive and training devices that could strengthen healthcare delivery. This course equips you with the knowledge and practical skills to address these issues using filament 3D printing technologies.

A hands-on approach
Participants will explore how 3D printing can be used to design and manufacture spare parts for biomedical equipment, as well as to create low-cost assistive tools (such as mobility aids and adaptive devices) and training models that support clinical education. Through hands-on modules, you will understand the core principles of additive manufacturing and gain familiarity with 3D printing tools, materials and techniques suitable for healthcare contexts. Using CAD software, students will learn to design replacement parts and apply principles of iterative prototyping to improve design quality and performance.

Beyond design, the course also focuses on how to operate and maintain low-cost 3D printers, troubleshoot common issues and ensure that printed components meet safety and functionality standards. You will be introduced to practical case studies and real-world examples to understand the challenges and opportunities of implementing 3D printing in resource-limited healthcare contexts.

By the end of the course, you will be able to independently design, produce, and evaluate spare parts, assistive devices and training tools using 3D printing. You will also be empowered to contribute to open-source communities and implement sustainable repair practices in your own institutions or regions. This course has the potential to significantly enhance your professional impact, allowing you to extend the lifespan of medical equipment, reduce downtime and improve healthcare delivery in resource-constrained settings.

Syllabus

Module 0: Welcome and orientation: get familiar with the course structure, objectives and learning community.

● Overview of course goals and structure

● Introduction to instructors and fellow participants

● Setting personal learning goals

● Learn how to participate in forums and assignments

Module 1: Foundations of 3D polymer printing: tools, techniques and materials

● Principles of additive manufacturing (FDM)

● Key components of a 3D printer and 3D printing workflow

● Benefits and limitations of 3D printing in healthcare

● Overview of materials (PLA, PETG, ABS, PP) and their biomedical applications (spare parts, assistive and training devices)

● Case examples of 3D printing in hospital practice

Module 2: Designing for biomedical applications with CAD

● Installing and setting up CAD software

● Sketching and modelling functions (extrude, revolve, sweep, loft, etc.)

● Designing spare parts, assistive tools and training models

● Exporting to STL and slicing for printability

● Post-processing basics (support removal, smoothing, coatings)

● CAD design assignment: replicate a biomedical part

Module 3: Setting up, troubleshooting, and maintaining a 3D printer

● Unpacking, assembling and calibrating a printer

● Loading filament and preparing a print

● Routine maintenance and low-resource adaptations

● Diagnosing and solving common print issues (clogs, warping, under-extrusion)

● Applied case studies in low-resource settings

Module 4: Exploring 3D printing solutions for healthcare needs in resource-limited settings

● Challenges: spare part scarcity, lack of assistive and training devices

● Why donated devices often fail

● Systemic barriers (supply chains, regulation, logistics)

● Identifying feasible applications of 3D printing (what to print, what not to print)

● Case studies: evaluating “print or not to print?” scenarios

● Enablers and barriers to adoption in low-resource settings, such as those found in some low- and middle-income countries (LMICs)

Module 5: Applying 3D printing in practice

● Principles of biomedical design: form, fit, function

● Designing for printability and functionality

● Iterative prototyping: design, test, refine

● Clinical integration: safety, sterilization, quality control

● Discussion: propose a local healthcare 3D printing solution

● Peer review and reflection

Wrap-up: Reflection and future practice

· Summarize key takeaways

· Reflect on learning outcomes and projects

Engage with the open-source global health 3D printing community

Taught by

Jenny Dankelman, Tim Horeman and Arjan Knulst

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