To help injured animals regain mobility and improve their quality of life, Bionic Pets LLC provides custom-made veterinary prosthetics and orthotics. The company works closely with pet owners and veterinarians to deliver tailored solutions ranging from full to partial prosthetic limbs to protective helmets, addressing a wide range of congenital and acquired conditions. As a trusted partner in veterinary care, the company focuses on helping animals regain their independence, restore confidence in their movement, and support long-term well-being.

Bionic Pets operates a fully in-house, on-demand manufacturing workflow tailored to each animal’s specific goals and needs. Production is driven by immediate patient needs, requiring customized prosthetic designs tailored to each individual’s size, weight, and activity level.

Specializing in professional grade veterinary orthotics and prosthetics, Bionic Pets operates completely within the veterinary medical device segment to serve animal owners and veterinarians globally. Prosthetics are fully customized and tailored to each animal’s unique anatomy, weight, and activity level. Devices are designed to meet the functional and mobility needs of the individual animal, ensuring comfort and durability for day-to-day life.

Bionic Pets required a custom system that enabled highly customized prosthetic feet, specifically adjusting to thickness and stiffness based on each animal’s lifestyle. The company needed to produce soft, flexible component that could be produced on demand for fast turnaround times. In addition, they needed to reduce overall production time. 

Having relied on Raise3D E2 IDEX 3D printers for dependable dual-extrusion of parts, the demand for faster turnaround times for customized TPU 3D printing led the team to upgrade to the Raise3D E3 IDEX 3D printer. The new printer was designed for faster printing of flexible materials. Paired with the company’s Flexible Filament Auxiliary Feeder the system is capable of producing TPU prints of up to 200 mm/s and better print consistency. This allows Bionic Pets to print multiple iterations and colors within a single job—typically producing two parts per print cycle. Depending on the size and stiffness requirements of each prosthetic foot, print times were reduced to as quick as 1 hour, enabling flexible and responsive production scheduling.

Using Kexcelled’s TPU 95A filament, Bionic Pets was able to produce durable prosthetic components that adapt to different surfaces while providing shock absorption, comfort, and enhanced mobility for animals. Combined with Raise3D Filament Dry Boxes and Flexible Filament Auxiliary Feeder, this optimized workflow has led to improved print quality, higher material yield, and more efficient production of customized veterinary prosthetics.

Following the upgrade to the Raise3D E3 paired with the Flexible Filament Auxiliary Feeder and Filament Dry Boxes, Bionic Pets achieved measurable improvements in production efficiency, product quality, and manufacturing flexibility. Some of the key results included streamlined design iterations, on-demand manufacturing with shorter turnaround times to better meet individual patient needs. The company also got improved print performance, quality, and consistency with fewer gaps, holes, and stringing issues. They were also able to increase material efficiency and filament spool utilization.

Through the adoption of the Raise3D IDEX 3D printing solution, Bionic Pets successfully optimized its production workflow of custom veterinary prosthetics and orthotics. The transition to the E3 enabled more efficient manufacturing, improved part quality, and greater design flexibility, allowing the company to provide highly customized prosthetics and orthotics solutions that help more animals regain their mobility and independence.

*Images courtesy of Raise3D. 

For information: 

Raise3D 

Bionic Pets