Automated 3D-printed finger orthosis versus manual orthosis preparation by occupational therapy students: Preparation time, product weight, and user satisfaction

Study design Intra-subject cross-sectional study. Introduction Upper limb injuries often require wearing an orthosis. Today, orthoses are custom-made by the clinician or purchased as an off-shelf product. Although 3D printing is a popular solution, the design and adjustment of an orthosis model according to patient-specific anatomy requires technical expertise, often unavailable to the clinicians. Purpose of the study (1) To create a software that receives input of anatomic dimensions of the finger and automatically adjusts an orthosis model for patient-specific 3D printing and (2) to compare preparation time, product weight, and user satisfaction of occupational therapy students between the manual method and the automatic 3D printing method. Methods A custom code allows the user to measure five anatomic measurements of the finger. The code adjusts a swan-neck orthosis model according to the patient-specific measurements, and a fitted resized 3D-printable file is produced. We recruited 36 occupational therapy students (age 25.4 ± 1.9 years). They prepared two swan-neck orthoses for a finger of a rubber mannequin: one manually using a thermoplastic material and the other by 3D printing. The preparation time and orthosis weight were measured, and the subjects filled out a user satisfaction questionnaire. Results The weight of the 3D-printed orthosis was significantly lower than that of the manual orthosis; however, the preparation time was longer. The subjects were more satisfied with the fit, esthetics, overall process, and product of the 3D-printed orthosis. Conclusion The creation of an automated software for the patient-specific adjustment of orthoses for 3D printing can be the missing link for integration of 3D printing in the clinics.