A Feasibility Study of Splintage by 3D Scanning and Printing: Process and Evaluation of Current 3D Printing Material

Three-dimensional (3D) scanning and printing technologies enable the production of personalized rehabilitation splints, yet challenges such as scanning artifacts in complex anatomical areas (e.g., finger webs), lengthy post-processing, long printing times, and material limitations (e.g., brittleness and poor breathability) hinder routine clinical adoption. This feasibility study developed and evaluated a clinician-accessible protocol for fabricating cock-up wrist splints using 3D scanning (Creaform GO!SCAN 50 with VXelements 4.1), modeling (Materialise Magics), and fused deposition modeling printing with polylactic acid (PLA) on a MakerBot Replicator+. Five healthy participants wore the splints for one week, with user satisfaction assessed via the Quebec User Evaluation of Satisfaction with Assistive Technology (QUEST 2.0; average total score 4.14/5, range 3.75-4.42) questionnaire. An experienced occupational therapist provided expert feedback. High satisfaction was reported for weight (4.6/5) and ease of use (4.6/5), confirming advantages over traditional thermoplastic splints in lightness and esthetics. However, lower scores for durability (3.6/5), comfort (3.6/5), and effectiveness (3.6/5) stemmed from PLA brittleness (cracking under load or overtightening), rough surfaces despite vapor polishing, inadequate ventilation causing moisture buildup, and fit issues (e.g., pressure points). Printing time averaged 9-19 h per splint. The protocol demonstrates proof-of-concept feasibility for clinicians with basic computer techniques, but material constraints and process refinements are required for reliable application in patient populations.