Considerations on the Design, Printability and Usability of Customized 3D-Printed Upper Limb Orthoses

This paper investigated the feasibility of using 3D printing processes, specifically material extrusion (MEX) and vat photopolymerization (DLP—Digital Light Processing), to produce customized wrist–hand orthoses. Design, printability, and usability aspects were addressed. It was found that minimizing printing time for orthoses with intricate shapes, ventilation pockets, and minimal thickness is difficult. The influence of build orientation and process parameters, such as infill density, pattern, layer thickness, and wall thickness, on printing time for ten parameter configurations of orthoses in both ready-to-use and flat thermoformed shapes was examined. The findings revealed that the optimized orientations suggested by Meshmixer and Cura (Auto-orient option) did not reliably yield reduced printing times for each analyzed orthoses. The shortest printing time was achieved with a horizontal orientation (for orthoses manufactured in their ready-to-use form, starting from 3D scanning upper limb data) at the expense of surface quality in contact with the hand. For tall and thin orthoses, 100% infill density is recommended to ensure mechanical stability and layer fill, with caution required when reducing the support volume. Flat and thermoformed orthoses had the shortest printing times and could be produced with lower infill densities without defects. For the same design, the shortest printing time for an orthosis 3D-printed in its ready-to-use form was 8 h and 24 min at 60% infill, while the same orthosis produced as flat took 4 h and 37 min for the MEX process and half of this time for DLP. Usability criteria, including perceived immobilization strength, aesthetics, comfort, and weight, were evaluated for seven orthoses. Two healthy users, with previous experience with traditional plaster splints, tested the orthoses and expressed satisfaction with the 3D-printed designs. While the Voronoi design of DLP orthoses was visually more appealing, it was perceived as less stiff compared to those produced by MEX.