Optimizing cranial orthotic design: Experimental evaluation of thermal comfort in 3D-printed vs. thermoplastic orthoses

This is the authors' abstract. We don't add key points for this paper.

Cranial remodeling orthoses (CRO) are essential in the treatment of positional cranial deformities of newborns. Traditional CROs, made from thermoplastic materials, often have limited ventilation, affecting thermal comfort and patient compliance. Recent advances in 3D printing offer new possibilities for optimizing airflow and material properties. However, a lack of comparative studies on the thermal behavior of 3D printed versus thermoplastic CROs remains a significant research gap. This study experimentally evaluated the thermal performance of two types of CRO: a conventional thermoplastic model and a 3D printed design. Infrared thermography was used to measure temperature changes in three identical pediatric head models under controlled conditions. A novel computational framework ensured consistent measurement across different orthotic designs. For both orthoses, thermal and evaporative resistance was measured using a thermal manikin according to ISO 15831. The thermoplastic CRO showed a drop in temperature from 3.6 to 5.0 ° C per hour. In contrast, the 3D printed CRO showed a faster cooling rate of 3.9–5.6 °C per hour. The tests performed on the thermal manikin confirmed a 20% reduction in the resistance to water vapor and a more gradual development of thermal resistance in the 3D printed CRO. These findings highlight the need for standardized CRO-specific thermal assessment protocols. This study provides the first direct comparison of thermal performance in 3D-printed and thermoplastic CROs. The results support a shift toward thermally optimized, patient-centered CRO solutions.