Learning methods through 3D printing

To help improve the health of lower limbs at high risk of ulcers, researchers at the University of South Australia (UniSA) have developed a method: they create realistic ulcers using 3D printed legs, icing sugar, chicken broth and flexible resin. Therefore, students can learn to treat risky foot conditions.

“True management and treatment of serious foot conditions is an essential pediatric skill, especially given the steady increase in type 2 diabetes in our population,” said Dr. Helen Banwell, who developed the method with Dr. Ryan Causby. Both are researchers at UniSA.

“Foot care is incredibly important for people with diabetes because even a small cut can lead to catastrophic consequences, including foot ulcers, lower extremity injuries or amputations,” Banwell added.

Learning methods through 3D printing

This method is also the first global podiatry initiative and involves 3D printing the shape of a foot with wound-like cavities and then adding the mixture of sticky substances to some models to mimic diabetes-infected wounds.

Banwell explains that over the last 20 years there has been a 30% increase in lower limb amputation rates and 85% of cases were caused by a leg ulcer that could have been prevented. «The most effective way to manage these conditions is to medically remove dead or damaged skin to expose healthy skin underneath and encourage healing. But learning the necessary scalpel skills is challenging due to the risks of ‘practicing’ a high-risk population,» adds Banwell.

The solution? 3D printed legs! Here the UniSA podiatry team has to be creative to create ulcers and similar effects. The mixture created from chicken broth and powdered sugar is used to create a leg ulcer, which the team must also invent to mimic many other conditions, from dry gangrene to pus. The results improve student learning and could also save infected limbs.

“The 3D leg models and the unbeatable lesions with which we enhance them allow us to provide a realistic yet safe learning tool for students to practice their scalpel skills without the stress or anxiety of treating a real patient,” Banwell continues.

Researcher Helen Banwell encourages learning through new technologies, which is why this 3D printing project is not the only one underway at UniSA.

Conclusion

The pioneering podiatry initiative described utilizes 3D printing to create a highly effective, risk-free educational tool aimed at combating the alarming 30% increase in lower limb amputation rates over the last two decades, 85% of which stem from preventable leg ulcers. The core innovation lies in the creation of realistic foot models featuring detailed wound-like cavities and incorporating sticky substances to accurately mimic the characteristics of diabetes-infected wounds. This level of realism, achieved through additive manufacturing, is crucial for simulating clinical conditions.

This technology allows medical professionals and trainees to learn and practice critical scalpel skills—specifically the necessary medical removal of dead or damaged skin (debridement) to expose healthy tissue—in a safe, controlled, and repeatable environment. By eliminating the inherent risks associated with practicing complex procedures on the high-risk patient population, 3D printing provides the most effective way to develop and refine the necessary surgical competence. Ultimately, this initiative directly addresses the challenge of preventing catastrophic outcomes from treatable conditions, offering a scalable, cost-effective solution for improving global podiatric education and, consequently, patient health outcomes.