Icarus Medical Uses SBA Financing to Expand Made in America Mobility Technology

SBA-backed financing helped Charlottesville-based Icarus Medical scale U.S. manufacturing, create local jobs, and bring customized orthopedic technology to more people with mobility challenges.

Founded by engineer and CEO Dave Johnson, Icarus Medical develops orthopedic braces designed to help people manage knee pain, improve mobility, and remain active. What began as Johnson’s effort to address his own knee injury has grown into a Charlottesville manufacturer creating patient-specific devices for people across the country.

Start with a mission

Johnson’s interest in better orthopedic support started after a football injury as a teenager left him searching for a brace that was comfortable enough to wear and effective enough to keep him active.

Years later, a knee surgery left Johnson with more serious mobility challenges and renewed his search for a better solution. He modified a post-operative brace, tested different mechanisms, and refined the design into a product that could support the knee as a user bends and rises.

“We make assistive joint braces. Our claim to fame is a brace that unloads behind your kneecap. So basically, when you bend down, it springs you back up. And that’s the brace that I personally wear every day because of my own injury.” – Dave Johnson

Johnson’s personal effort to stay active became the foundation for Icarus Medical. He saw that the technology could help people whose mobility was limited by knee pain, arthritis, neurological conditions, or complex orthopedic injuries. The company now makes individualized braces for people who may otherwise face limited options beyond a walker, wheelchair, or surgery.

Access to SBA capital

Johnson left a stable federal role in the intelligence community during the COVID-19 pandemic to build Icarus Medical. As demand grew, the company needed capital to hire employees, build a sales network, support operations, and expand manufacturing.

Icarus initially relied on outside production for its 3D-printed devices, but scaling required bringing manufacturing in-house. As a young manufacturer, Icarus had to prove that demand was real and find financing that could keep up with it.

In 2021, Icarus secured an initial SBA-backed financing package that helped the company buy equipment, bring production in-house, and build the operational foundation to serve more patients.

“SBA was the only partner serious about providing the capital and backing we needed. They helped us organize and structure the business, and we really wouldn’t be here without them.” – Dave Johnson

In 2023 and 2025, Icarus secured additional SBA-backed financing to support its next stage of growth. The capital helped the company expand its product family from one product class to six and pursue international growth.

Results of SBA support

With SBA financing in place, Icarus added production capability and expanded its workforce. The company operates six 3D-printing systems and produces individualized orthopedic devices. Using digital design, 3D scanning, and 3D printing, Icarus can tailor each device to a patient’s anatomy and mobility needs.

“We’re a serious employer now. It started off with just me in 2019, 2020. Now we’re up to 70 employees, and we’re continuing to grow.” – Dave Johnson

Icarus fulfills roughly 100 orders per day. They now offer six product classes including knee braces for different conditions, ankle and foot-drop assistance, and integrated mobility devices for people with more complex orthopedic needs.

The company also works with clinicians and orthotists on complex cases that conventional braces cannot address. In-house manufacturing lets Icarus refine designs quickly, respond to patient needs, and maintain close quality control. 

Made in America impact

Icarus manufactures in the United States because customized care depends on quality control and the ability to improve products quickly. Johnson said outsourcing would make it harder to maintain the oversight and speed required to respond to individual patient needs.

Many orthopedic devices on the market are manufactured overseas, including in China and Mexico. Icarus chose a different approach: keeping design and production close to its Charlottesville team so it can oversee quality, make changes quickly, and respond to the needs of individual patients.

“We chose to build in the United States because quality and speed matter. When a patient needs something better, we need the ability to improve it quickly and get it to them.” – Dave Johnson

SBA Deputy Administrator Bill Briggs toured Icarus Medical on July 13 to see how SBA support was helping the company expand. He said Icarus reflects the type of small manufacturer SBA aims to support through its Made in America manufacturing initiative.

“It’s part of what we’re trying to do at SBA, which is encouraging local manufacturing and hiring of local employees and growing the local economies and having a national impact. And Icarus is certainly doing that.” – Bill Briggs, SBA Deputy Administrator

Icarus works with physicians and orthotists to help patients access braces through insurance or Medicare, while also offering direct-purchase options for some customers.

Final thoughts

Looking ahead, Icarus Medical plans to expand its product line, continue hiring, and bring its technology to more people living with pain and mobility challenges. The company is especially interested in reaching service members and veterans whose knee pain or overuse injuries can limit their mobility and ability to remain active.

For Johnson, the long-term goal is to build a company that can continue serving patients without depending on him alone. Icarus Medical’s growth shows how SBA-backed capital can help an innovative small business move from a founder’s personal idea to a company improving patients’ lives while creating high-quality local jobs.

To learn more about SBA capital products and financing options for your small business, visit www.sba.gov/loans/.