Customized Wrist Immobilization Splints Produced via Additive Manufacturing—A Comprehensive Evaluation of the Viable Configurations

Orthopedic splints are external medical devices designed to support and protect the functions of the human musculoskeletal system from pathological conditions or traumatic events. Tailoring these medical solutions to the morphology of the patient’s limb is essential to ensure a correct and rapid rehabilitation pathway. Although traditional splinting techniques might achieve a unique fit, the procedures are highly dependent on the skill and experience of the medical operator, affecting the quality of the care treatment. In response to the drawbacks associated with traditional splinting techniques, the present article proposed an innovative and structured methodology to manufacture customized wrist immobilization splints, prioritizing simplicity and user-friendliness in fabrication activities. The customized splint manufacturing was based on the integration of reverse engineering (RE) and additive manufacturing (AM) techniques. The research designed a baseline model of a wrist splint, varying over different thickness values and manufacturing materials (ABS, nylon, PLA, PC, PA6-GF25, PA6-CF20). For every splint model, the production times and material costs were assessed. Technical tests were performed via finite element analysis (FEA). The conducted analysis and the resulting charts empower medical perators to select the most appropriate solution, ensuring a well-informed and effective decision-making approach.