Design of Upper and Lower Limb Orthoses

Introduction

This project aimed to design and develop customizable 3D-printed orthotic splints for upper and lower limbs, focusing on Thumb Spica, Toe Splint, and Stack Splint. These orthoses were designed to provide optimal fit, comfort, and functionality for medical applications.

Methods

• Design development — Created digital models for the Thumb Spica, Toe Splint, and Stack Splint using computer-aided design (CAD) software, incorporating features like breathable patterns and ergonomic shapes for enhanced usability.
• Material selection and testing — Chose Polylactic Acid (PLA) for its lightweight and durable properties, and tested the material for heat malleability to enable easy customization during patient fitting.
• Fabrication — Used 3D printing technology to produce splint prototypes, ensuring accurate production of custom-fitted designs tailored to individual patient anatomy.
• Evaluation — Conducted user trials with patients and medical practitioners to assess fit, comfort, and functionality.

Results

• The project successfully delivered high-quality 3D-printed orthotic splints tailored to individual patient anatomies for optimal comfort and fit.
• Polylactic Acid (PLA) was utilized for its lightweight, durable, and heat-malleable properties, enabling easy customization for patient-specific adjustments. The breathable, ergonomic designs were easy to wear and proved effective for medical applications.
• Splints were cost-effective and reproducible using widely available 3D printing technology.
• Both patients and practitioners reported high satisfaction levels with the splints' performance and comfort.