3DStride: Ultra-Affordable, 3D Printed Crutches

Introduction & Story

3DStride is an open-source crutch design created for communities in need—where commercial mobility aids are often out of reach.
This project began through a chance connection with Svend and his son Charlie, who were supporting amputees in Sierra Leone after the civil war. Svend and Charlie originally reached out to me as customers, but soon, conversations turned to ideas for real-world impact with 3D printing.

In those conversations, Svend asked:

“What if we could 3D print crutches for people in Sierra Leone?”

It was the spark for 3DStride.
I started designing: a crutch that’s printable on a standard FDM printer, strong enough for daily use, and cheap—about $12 per pair, using a few bolts, an aluminum pipe, and ASA filament.

Everything took a big step forward when Svend invited me to Denmark to meet with a group of amputees from Sierra Leone, members of an amputee football team who had come to Europe for a special event. Hearing their stories and seeing firsthand the daily challenges they face made it crystal clear—mobility is a human right, but for many, it’s just not available. So I’ve build first prototype and took with e to Denmark.

As the design progressed, the project grew. I connected with Kevin, a passionate STEM teacher and 3D printing enthusiast in Kenya, who was eager to help. Kenya faces similar challenges with disability and access to assistive devices, but also with plastic waste.

So, I sent Kevin not just the crutch designs, 3D printer and ASA filament—but also a PETmachine.
The idea? To empower his school and community to turn discarded plastic bottles into 3D printing filament, and literally create crutches from waste. This approach makes 3DStride even more accessible and sustainable—solving both mobility and plastic pollution challenges at once, while teaching valuable STEM skills.

Motivation

• Problem: Many people in Sierra Leone and Kenya suffer limb loss due to war or injury and cannot access or afford basic crutches.
• Consequence: The only alternative is crawling—limiting mobility, dignity, and opportunities.
• Goal: Create a crutch that is affordable, strong, easy to make, and adaptable to local conditions.

Design Overview

• Cost to Produce:
  • Total cost per pair: ~$8-14 (filament, hardware, pipe, electricity).
  • Designed for production in community makerspaces or schools.

• 3D Printed Components: Main frame, handles, arm support, and foot.
• Additional Parts:
  • Standard aluminum 20×2 pipe (commonly available)
  • 4x M6 DIN 7991 bolt
  • 4x M6 DIN 985 nut
• Material of Choice:
  • ASA filament—chosen for its durability, UV/weather resistance, and ease of printing.
  • TPU 95A—great anti-slip properties for the bottom part.
  • Tested with PLA, PETG, but ASA provided the best strength/printability ratio and heat resistance.

Assembly Instructions

• All 3D printed parts can be printed on a standard FDM printer (250x250mm bed and closed chamber recommended).
• Typical print time: ~17 hours per crutch (Wall loops = 8; Infill density = 30%; Infill pattern = Gyroid).
• Material usage: 500g per crutch.
• After printing, parts are assembled using basic tools (allen key).
• The aluminum pipe is cut to user height.
• All files, BOM, and instructions are open-source and available for download (link on the very bottom of this page)

Testing & Results

• Durability Tests:
  • Tested with users up to 80kg (175lbs) on concrete and uneven ground.
  • ASA crutch survived drop tests, outdoor sun, and rain.
• User Feedback:
  • Prototypes used by members of the Kenyan amputee football team (still waiting for a full feedback).
  • Positive feedback on weight, comfort, and stability.
  • Ongoing testing for further improvements (ergonomics).

Sustainability

• PETmachine Integration:
  • Filament can be produced from recycled plastic bottles using PETmachine®, reducing cost and plastic waste.

Impact & Next Steps

• 6 pairs in current field test.
• Seeking collaborators:
  • Makers, NGOs, schools—help us test, iterate, and distribute.
• Looking to expand to more teams and communities.

Download & Resources

• Files and assembly instructions: You can find them here!
• Contact for Feedback/Collaboration: igor@tylmandesign.com