The Podiatry EduKit

The design process began with getting a deeper understanding of the problem. Insights were gathered directly from the students who had experienced the issue firsthand. Considerations such as functionality, cost and realism were mapped out to determine a balance that would best meet the needs of the teaching environment. Similar existing solutions were researched and their pros & cons were analysed.

Several early prototypes were created and tested by Dr Ho’s students. Their feedback shaped each stage of the design, ensuring that user centred design principles were followed closely. Many improvements to usability and performance would likely have been missed without these testing sessions, which proved crucial in refining the product.

Although a higher level of anatomical accuracy was technically achievable, such as including bones or a full lower limb, it was recognised that cost and practicality were more important to both students and institutions. A balance was reached, where the kit remained realistic and functional while staying affordable and accessible. Aesthetics were also considered carefully. In contrast to the harsh, clinical appearance of existing tools, the EduKit was designed with soft pastel colours and approachable forms to help students feel more comfortable when using it. Production was a key design constraint.

Demand for the kits is too low for injection moulding, yet too high for hand-built units. To address this, the design was tailored for large format FDM 3D-printing using Monash Automation’s Matrix print farm. This allowed scalable production without expensive tooling. Every plastic component in the kit was designed with FDM-specific considerations, including material flow, tolerances, support removal, and surface finish. Parts were also optimised for simple assembly and durability.

By adopting additive manufacturing early, a cost effective, scalable pathway was created, ensuring the EduKit could be efficiently deployed without compromising on usability or realism.

The Podiatry EduKit delivers a highly functional, user-centric solution that offers a new approach to how hands on learning tools can be delivered in a cost-effective and user-friendly way. Designed for podiatry students to practise debridement and nail care, the kit achieves exceptional realism with its anatomically accurate, flexible 3D printed foot.

The robust foot clamp accommodates hospital beds and teaching stations, and features a wide range of motion to simulate real patient variability, while the inclusion of removable wax callus inserts and plastic nail modules enable repeatable practice at minimal ongoing cost. This all combines to help students build muscle memory with confidence. Importantly, inclusivity was embedded in the design, with kits available in multiple skin tones to better reflect the diversity of real patients which is an issue still often overlooked in educational health models. Further, the clean, pastel-toned aesthetic brings some warmth to the market where the cold and sterile look is the norm, making the product feel approachable and less intimidating for students. Every design choice prioritised accessibility, safety, and usability.

Extensive prototyping and feedback from students and educators ensured that the final product not only met technical and functional requirements but also fit seamlessly into existing teaching environments. By leveraging large-scale FDM 3D printing, the EduKit avoids the need for traditional tooling, enabling low-volume, cost-effective production without compromising quality. It provides more functionality than any current solution on the market at a fraction of the cost.

The Podiatry EduKit represents a thoughtful and practical response to a clear gap in medical education. The project demonstrates how simple good design can meaningfully improve educational experiences and support better outcomes for students and institutions alike, both in Victoria and more broadly.

The Podiatry EduKit was developed to address a clear gap in podiatry education - the lack of realistic & accessible hands on tools for practising essential procedures. Prior, students have had limited opportunities to build confidence before entering clinical environments.

This project approached the problem by focusing on low-cost production, thoughtful design-for-manufacture, and user-centred design. To achieve this, a key innovation lies in the use of ColorFabbs Varioshore foaming TPU, which gives the 3D printed foot its soft, skin-like feel while remaining lightweight and durable. This relatively novel material is rarely used in educational models and provides a significant leap in realism.

The product is also manufactured using Monash’s automated large-scale FDM print farm, enabling small-batch scalability without the need for costly tooling, allowing for high quality, repeatable output at a fraction of traditional manufacturing costs. Throughout development, feedback was consistently gathered from educators and students. Multiple iterations were tested and refined to ensure that the design met classroom needs.

The response has already been overwhelmingly positive, with students reporting greater confidence and engagement in their learning. By applying design-for-manufacture and user centred thinking in parallel, a functional, accessible, and more engaging training solution was delivered to an overlooked area of health education.

In the few short months since the Projects completion, the Podiatry EduKit has already been sold to Monash Universitys Masters of Podiatric Care course and Monash University Malaysias Masters of Wound Care course, and interest from a few other institutions across Australia. Since then, students have reported improved confidence when practising debridement and nail care, thanks to the increased realism and repeatability of the training experience. For students who may have had limited opportunities to practise on real patients, the kit provides a vital stepping stone, helping bridge the gap between theory and clinical experience.

The project prioritises sustainability by directly recycling all 3D printing waste into new filament for future parts. Efforts are also underway to source materials made from already recycled plastics, ensuring the production process supports circular economy principles and minimises environmental impact without compromising quality or function.

Beyond its use in podiatry, the EduKit highlights how design and engineering can work together to improve education in specialised healthcare fields. It stands as an example for other medical departments and research groups, showing that high quality, hands on learning tools can be developed quickly and affordably with the right approach. In doing so, it contributes to Victoria’s growing reputation as a place where design-led innovation can thrive across disciplines, particularly within education and medtech.