Open Bionics: The Hi-Tech Prosthetics Turning Disabilities Into Superpowers

Damian leads us to the cover wall - a standout feature. “So many prosthetics used to be made to look like real limbs. We do the opposite,” he says. Rather than blend in, Open Bionics arms are meant to stand out. “We want to give people ways to express themselves.” Thanks to licensing deals with Marvel and Disney, they offer themed covers like Iron Man or Elsa. “When Moana 2 launched, we created a custom set for a young girl in the States,” Damian shares. The covers are swappable, letting users choose the look that best represents them. “It becomes a fun part of their identity - not something to hide.”

Open Bionics began over ten years ago, founded by Joel Gibbard and Samantha Payne. “They came together from the robotics scene here in Bristol,” says Damian. The goal? Rethink how prosthetics are made and how they’re perceived. “We don’t want to make bland products that hide away,” he says. Their approach is rooted in inclusion and creativity. “Instead of being ashamed, or in the case of kids, ridiculed, our users feel empowered.” Their ethos, “turning disabilities into superpowers,” drives every design choice. The Hero Arm allows users to show off their personality, with the technology becoming a point of pride.

Inside the Hero Arm are miniature linear actuators - tiny motors that drive a threaded rod, moving a nut along its axis. “That nut pulls on a tendon, which is similar to a fishing line,” Damian explains. These tendons run into the fingers, enabling them to open and close. “It’s very analogous to how our natural hands work.” The hand’s movement is activated by muscle signals detected via EMG sensors. This mechanical-biological harmony allows for intuitive control. “You flex your muscle, and the fingers respond,” he says. The Hero Arm's engineering mimics natural anatomy while giving users the ability to perform everyday tasks with ease and confidence.

Creating a prosthetic that’s light and comfortable is a constant challenge. “Traditional sockets are heavy and sweaty,” says Damian. “They’re hard to wear for more than a few hours.” Open Bionics turned to 3D printing early on. “We started with hobbyist printers, but now we use industrial methods.” This approach allows them to make breathable, lightweight, custom-fitted arms. “Until a couple of years ago, the rest of the industry saw it as a gimmick,” he says. But things have changed. “Now, 3D printing is everywhere.” Open Bionics has led the way, and their Hero Arm remains one of the lightest on the market - and one of the most comfortable, too.

Evie from the marketing team shares real-world examples. “We hear from people of all ages - from five to eighty-two,” she says. A child in New York uses their Hero Arm to ride a scooter and blow bubbles. Another user returned to farming after an accident. “We’ve got clinics across the UK, Europe, and six in the US,” she adds. Tori, an athlete from Colorado, is training for the 2028 Paralympics. “She’s just been fitted with two Hero Flex arms so she can ride her bike,” says Evie. “We love hearing how people use our tech to chase their goals.” These stories prove that prosthetics can be powerful tools of independence and ambition.

Open Bionics values community feedback. “So many of our features started with suggestions from users,” says Evie. Whether it’s grip strength, design tweaks, or comfort adjustments, they listen closely. “We always hope our technology is tested to the limit,” she adds. That real-world testing ensures products meet user needs in diverse situations. “We love seeing how people adapt it to fit their own lives.” This co-creation model leads to smarter innovations. “A lot of it starts with, ‘Wouldn’t it be cool if…?’” The result is a prosthetic that feels personal and evolves in step with its users.

Damian didn’t start in prosthetics. “I studied cybernetics, but spent years in corporate FMCG,” he says. He worked on products like snack food before joining Open Bionics. “I always wanted to do something more socially focused,” he shares. A friend who worked at Open Bionics encouraged him to apply. “I leapt at the chance - and never looked back.” The opportunity to combine meaningful impact with technical innovation was irresistible. “It’s one of the best places I’ve ever worked,” Damian says. At Open Bionics, he’s finally using his skills in a way that truly changes lives.

Damian sees a bright future for prosthetics. “We want to halve our delivery time - maybe even faster,” he says. Right now, a limb can take four weeks, but new methods could shorten that significantly. He also sees prosthetics becoming more affordable and accessible to younger users. “Refitting kids is expensive. We want to change that.” Technologically, the next leap will involve new sensors. “EMG can only go so far. We need something more robust,” he says. AI may play a role. “It’s already being tested in labs to interpret nerve activation.” With advances in power and computing, that future may not be far off.

Jon Hirschtick from PTC outlines how Open Bionics benefits from using Onshape, their cloud-native CAD platform. “Onshape allows them to configure multiple versions without needing separate files,” he says. That flexibility saves time and reduces errors. “They’ve cut design time on prosthetic wrists and hands by more than 75%.” Onshape’s branching and merging features allow engineers to try different ideas quickly and gather real-world feedback. “It also boosts collaboration between hardware, electrical, and firmware teams.” Best of all, it’s fully cloud-based. “No servers, no special workstations - it just works,” Jon says.