Milwaukee VA Medical Center
VA therapists combine 3D printing, creativity
A custom joystick created with a 3D printer allows Jim Borelli to independently operate his wheelchair (photo by Benjamin Slane).
The standard joystick options on power wheelchairs did not meet the needs of Jim Borelli.
Borelli, who sustained a spinal cord injury resulting in quadriplegia in 2018 after falling down a flight of stairs, was unable to maintain contact with the round surface of the joystick to control his power wheelchair.
But thanks to a combination of creativity and logical analysis, and the use of a 3D printer, physical and occupational therapists at the Milwaukee VA were able to create a specially designed rectangular joystick that allows Borelli to operate his wheelchair independently.
“I would drive the chair maybe five or ten feet before slipping off the [joystick],” said Borelli. “It was very frustrating and made life more difficult than it already was.”
Borelli’s physical and occupational therapists tried a variety of solutions without success.
“They were banging their head against the well, trying various methods - six different joysticks - without any real headway,” said Katie Schultz, a physical therapist and assistive technology professional with the Spinal Cord Injury Center at the Milwaukee VA.
After watching Borelli’s arm and shoulder movements, Schultz realized the issue was the shape of the joystick. With a computer-assisted design (CAD) program, Schultz created a rectangular joystick that was made on the 3D printer – at a cost of roughly $3 in printer filament.
Almost immediately after installing the custom joystick, Borelli was independently operating his wheelchair.
“It was the first time since he was injured that he was able to drive his power wheelchair,” Schultz said. “That opens up a world. The fact that you can leave your hospital room and actually go out and talk to people in the hallway. That’s huge.”
With the 3D printer, therapists were able to create a rectangular joystick to replace the round one, which Borelli could not easily operate (photo by Benjamin Slane).
The Milwaukee VA was able to purchase the 3D printer through the VA Innovation Grant Program. Schultz and her colleagues, Katie Powell and Jaclyn Raab, wrote the grant, completed a CAD training course, and worked with a mentor in Rehab Engineering from the Richmond VA to establish their program. The Milwaukee 3D Design and Printing program is the only 3D printing program within the VA system operated by therapists.
“What makes us different, what makes us a complete standout, is that we are the only 3D printing program that is run by therapists,” Schultz said. “Every other 3D printing program in the country has a rehab engineer as a part of their team.”
In addition to cost savings, Schultz said 3D printing has greatly reduced the time needed to produce individualized equipment.
“For me, the clincher is time,” she said. “We’ve gone from 6 to 8 weeks, down to 3 or 4 days. Not only are you saving time, now the Veteran has that in their possession much sooner. That is the part that continues to amaze me, day in and day out.”
Schultz said using the 3D printer to help Borelli and other Veterans is its own reward.
“Working within the confines we have, we were able to give him more independence,” said Schultz. “That is the reward, changing lives.”
