Apr 19, 2025 
Sam Onukuri has over 30 years of experience in the R&D and commercialization of medical devices, as well as an extensive background as a materials scientist throughout his career. He is currently engaged in advancing innovation with various Industry thought leaders, healthcare practitioners, and 3D printing technology providers. He serves on the Medical Advisory Board for Addup Corporation, specializing in Metal 3D printing systems for Healthcare, aeronautical, and industrial applications. He also provides Consulting services to various healthcare companies and to a not-for-profit 3DP4ME.org, which is serving hearing-impaired children in the Middle East using 3DP technologies. Previously, as the Head of Johnson & Johnson 3D Printing Innovation and Customer Solutions, Sam Onukuri led the integration of 3D printing across various businesses, evolving the way products and solutions are created and delivered. He and his dedicated team advanced new materials and 3D printing technologies to innovate the design, manufacturing, and delivery ecosystem. Sam worked closely with R&D, Supply Chain, Commercial, Quality, Regulatory, Legal, and IT to drive 3D printing initiatives across J&J’s medical device, consumer, and pharmaceutical businesses. Those initiatives include bioprinting, point of care solutions, precision medicine, electronics and sensors, advanced metals and ceramics, polymers and natural materials and 3D enabled innovative designs. Before Johnson & Johnson, roles include Advanced/Front-end Technology leadership for Medical Devices and Senior Fellow within the Ethicon family of companies. Prior to Johnson & Johnson, Sam worked at General Electric and Baxter Healthcare. Sam currently resides in Cincinnati, Ohio, with his wife, Jeanne, and their two dogs, Guinness and Shamrock.
Show notes:
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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