Evaluation of patient preference in 3D printed cast and associated cost compared to current standard of care

Fracture incidence is rising globally, with traditional fiberglass casts commonly used for immobilization despite discomfort and hygiene issues. 3D printed casts offer similar or improved strength, better comfort, and breathability. While patient satisfaction is generally higher, data on cost-effectiveness and willingness to pay remain limited. This study examines patient preferences between 3D printed and traditional casts after being informed of potential benefits and costs. A PubMed review (2015–2023) identified 14 relevant studies on 3D printed casts. Cost data were obtained from Medicare/Medicaid and U.S. manufacturers. A patient survey was conducted at a single clinic (Feb 2024–Aug 2025) among individuals treated with fiberglass or plaster casts. Fifty responses were collected and analyzed using Excel. Of 50 patients, 66% were under 18 and 44% had wrist casts. Most rated immobilization as effective (72%), but 76% reported hygiene issues. About 78% were willing to pay for improved fit or hygiene. Private insurance was linked to greater willingness to pay, and a significant correlation was found between unwillingness to pay for both features (p < 0.001). Traditional casts are effective, but hygiene remains a key concern. Most patients were willing to pay for improved fit and hygiene, especially for wrist and elbow injuries. Interest in same-day casting and alternatives to splints was high. 3D printed casts may offer advantages over both fiberglass casts and CAM boots.