Assessment of the Mechanical Properties and Fragment Characteristics of a 3D-Printed Forearm Orthosis

Distal radius fractures (DRF) are one of the most prevalent injuries a person may sustain. The current treatment of DRF involves the use of casts made from Plaster of Paris or fiberglass. The application of these materials is a serious endeavor that influences their intended use, and should be conducted by specially trained personnel. In this research, with the use of the full-body 3D scanner Vitus Smart, 3D modelling software Rhinoceros 3D, and 3D printer Creality CR-10 max, an easy, yet effective workflow of orthosis fabrication was developed. Furthermore, samples that represent segments of the orthosis were subjected to static loading. Lastly, fragments that occurred due to excessive force were characterized with the use of a digital microscope. It was observed that with the implementation of the designed workflow, a faster 3D printing process was present. Samples subjected to mechanical loading had values that exceeded those of conventional Plaster of Paris; the minimum recorded value was 681 N, while the highest was 914 N. Microscopic characterization enabled a clear insight into the occurrence of fragments, as well as their potential risk. Therefore, in this research, an insight into different stages of fabrication, characterization of undesirable events, as well as the risks they may pose were presented.