The Fabrication of Requisite, Durable, Printed Upper Extremity Orthoses Through Innovative Means in an Austere Environment

3D printing enabled the timely fabrication of upper extremity orthoses during a period of equipment shortage at a deployed military medical facility. These devices were created to fulfill immediate clinical needs and were retrospectively evaluated using documentation from routine patient care. This study highlights the real-world feasibility of using 3D printing in constrained settings to deliver personalized orthopedic support when conventional DME is unavailable. Printers are moderately robust but sensitive to dust, temperature, and motion; ruggedized models and IP-compliant designs are recommended for austere use. Costs may exceed traditional initially but offer logistics savings. Multi-specialty applications justify deployment. Although limited by its retrospective design and absence of formal outcome tracking, the findings demonstrate the potential for 3D printing to reduce supply chain dependence, support operational autonomy, and enhance care delivery in deployed environments. Future research should evaluate the long-term durability, patient outcomes, and cost-effectiveness of 3D-printed orthoses and explore expanded applications across other forms of field-ready medical equipment to improve readiness in both military and humanitarian contexts.