Sam Onokori takes us through his remarkable 30-year journey at Johnson & Johnson, where he transformed the landscape of medical devices through pioneering work in 3D printing technology. As a material scientist who led the development of J&J's Center of Excellence for additive manufacturing, Sam offers rare insights into how a global healthcare giant approached innovation and personalized medicine.

The conversation reveals the fascinating evolution of medical 3D printing from basic prototyping to FDA-approved implants. Sam shares the story behind breakthrough products, such as the TrueMatch graft cage – a PCL-based, bioabsorbable scaffold for bone reconstruction that has dramatically improved patient outcomes. His candid assessment of where personalization succeeds (craniomaxillofacial implants) and where it falls short (knee replacements) provides a nuanced perspective rarely found in technology discussions.

We examine the unexpected challenges that have shaped the industry, including the complex regulatory landscape, the emergence of surgical robots, and the economic realities that have tempered some early expectations. Sam's firsthand experience with point-of-care printing initiatives and customized surgical instruments provides valuable lessons about striking a balance between innovation and practicality in healthcare settings.

Looking toward the future, Sam identifies promising frontiers, including bioprinting, advancements in materials science, and the integration of AI with 3D printing technologies. For students and professionals considering careers in this field, he emphasizes the importance of strong engineering fundamentals and experiencing both startup and corporate environments to develop a comprehensive skill set.

Whether you're a healthcare professional, engineer, investor, or simply curious about how medical innovation occurs, this conversation offers an authentic glimpse into the triumphs, setbacks, and unrealized dreams that continue to shape the future of personalized medicine and additive manufacturing.

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About Pitch3D

3DHEALS kicked off its first in-person/hybrid event in 2025 in San Francisco, welcoming investors, entrepreneurs, and innovators in the space. The healthcare industry is transforming, driven by 3D printing and bioprinting technologies redefining patient care. This exclusive in-person hybrid event offered an opportunity to explore the latest advancements in custom prosthetics, implants, bioprinted tissues, and scaffolds. The remarkable convergence of 3D printing and healthcare transforms medicine through customized solutions that weren't possible a decade ago. This episode brings together five leaders in the healthcare field who are harnessing additive manufacturing to solve real clinical problems and improve patient outcomes.

Summary:

• 3D-printed spinal implants have evolved from simple titanium cages to sophisticated expandable devices that restore alignment and relieve nerve compression
• Patient-specific radiation shields protect healthy tissue during cancer treatment, reducing devastating side effects like oral mucositis
• Bioprinted organoids are creating human-derived testing platforms for drug discovery
• 3D-printed trabecular metal structures are providing better bone integration for joint replacements
• AR/VR integration with 3D printing is a robust tool for surgical planning, training, and patient education..
• Evidence-based innovation remains critical, focusing on validated clinical problems rather than technology for technology's sake.
• The shift toward ambulatory surgical centers drives demand for minimally invasive solutions that 3D printing can uniquely deliver.
• Investment in medical 3D printing continues as clinical applications expand.

The experts emphasize that successful innovation must be evidence-based, addressing validated clinical problems rather than pursuing complexity for its own sake. The speakers agreed, "Just because it's complex doesn't mean it's better." This wisdom encapsulates the mindful approach needed as we continue exploring the vast potential of 3D printing in healthcare.

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Jenny and Matthew discussed the latest trends and innovations in the orthopedic and medical device industry, including regenerative medicine approaches for joint and spine conditions, new technologies like 3D printing and wireless endoscopes, and workflow management solutions to improve hospital efficiency after Matthew's recent blog about his AAOS 2025 experiences. They highlighted exciting startups like Genix, Osteal Therapeutics, and Ospitek that are disrupting traditional treatment paradigms. Matthew also shared his insights on the changing landscape of industry conferences and the potential impact of politics and regulation on medical innovation. Overall, the conversation covered a wide range of cutting-edge developments that could significantly improve patient outcomes and transform the future of orthopedics.

Introductions and background

Jenny and Matthew introduce themselves and provide background on their respective roles and businesses.

Trends at recent industry conferences

Matthew shares his observations from attending recent industry conferences like the Canaccord Genuity and AAOS events. He notes trends around decreasing surgeon attendance at the larger conferences, and increased interest in regenerative medicine and solutions for prosthetic joint infections (PJI).

Regenerative medicine innovations

Matthew highlights two promising regenerative medicine companies - DiscGenics, Osteal Therapeutics, which has an implantable pain relief solution. He discusses the potential for these innovations to disrupt traditional spine surgery

Advancements in surgical tools and workflow

Matthew discusses new technologies like wireless endoscopes from companies like Lazurite and single-use endoscopes from Pristine Surgical that are improving surgical visualization and sterility. He also highlights Ospitek, a company using real-time patient tracking to optimize hospital workflow and efficiency.

Potential impact of political changes

Matthew shares his perspective on how the new Trump administration may impact medical device companies.

Recap and future outlook

Jenny and Matthew conclude by discussing the dynamic and evolving nature of the medtech industry, and the importance of remaining optimistic about the potential for innovation to improve patient outcomes, despite political and economic uncertainties.

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Support the show

Follow us:
Twitter: https://twitter.com/3dheals
Instagram: https://www.instagram.com/3dheals/
Linkedin: https://linkedin.com/company/3dheals
Website: https://3dheals.com/
Facebook: https://www.facebook.com/3dheals
Facebook Group: https://www.facebook.com/groups/3dheals
Youtube channel: https://www.youtube.com/@3DHEALSINNOVATION

About Pitch3D:
https://3dheals.com/pitch3d/