Related Experiment Video
Updated: Jan 11, 2026
Creation of a High-Fidelity, Low-Cost, Intraosseous Line Placement Task Trainer via 3D Printing
Published on: August 17, 2022
The Fabrication of Requisite, Durable, Printed Upper Extremity Orthoses Through Innovative Means in an Austere
Manuela Gaviria1,2, Simon B Gott3, Andrew W Ellis4,5
1Department of Orthopaedics, Brooke Army Medical Center, 3551 Roger Brooke Dr., Fort Sam Houston, TX, 78234, United States.
Introduction:
In deployed military settings, ensuring consistent access to durable medical equipment (DME) remains a significant challenge due to logistical and supply chain limitations. This study retrospectively reviews the clinical use of 3D-printed upper extremity orthoses fabricated out of necessity at Al Udeid Air Base (AUAB), Qatar, in response to such shortages. Devices were implemented during routine care and assessed through provider documentation and photographic evidence. Although representative of logistics-supported Role 2s, the results may not fully extend to forward combat Role 2s without adaptations.
Materials And Methods:
A retrospective chart review was conducted for patients treated with 3D-printed orthotic splints between March and July 2024 at AUAB. Printers included a FormLabs 3B+ SLA and Creality CR-6 MAX FDM device, using Formlabs Draft V2 resin and Overture PLA filament. Devices were fabricated using an open-source design to meet immediate clinical needs, with print times of 1-2 h per splint. Variables extracted included splint type, application site, patient tolerance, and clinical utility as documented in the medical record.
Results:
Multiple splint designs were fabricated, including an en bloc thumb spica, a heat-moldable flat PLA splint, and a series of DIP extension splints for mallet finger injuries. The en bloc splint, printed using SLA resin, provided satisfactory fit and comfort with a stockinette liner and adjustable securing mechanisms (Figure 1). A flat PLA-based splint was customized at bedside through heat molding (Figure 2 and 3). Finger extension splints were printed in batch-scaled sizes and used for 8-week immobilization in 1 patient with a soft tissue mallet deformity (Figure 4). All splints were well tolerated, functionally effective, and enabled continuity of duty with minimal limitation. Compared to plaster, 3D prints offered better ventilation and durability.
Conclusions:
3D printing enabled the timely fabrication of upper extremity orthoses during a period of equipment shortage at a deployed military medical facility. These devices were created to fulfill immediate clinical needs and were retrospectively evaluated using documentation from routine patient care. This study highlights the real-world feasibility of using 3D printing in constrained settings to deliver personalized orthopedic support when conventional DME is unavailable. Printers are moderately robust but sensitive to dust, temperature, and motion; ruggedized models and IP-compliant designs are recommended for austere use. Costs may exceed traditional initially but offer logistics savings. Multi-specialty applications justify deployment. Although limited by its retrospective design and absence of formal outcome tracking, the findings demonstrate the potential for 3D printing to reduce supply chain dependence, support operational autonomy, and enhance care delivery in deployed environments. Future research should evaluate the long-term durability, patient outcomes, and cost-effectiveness of 3D-printed orthoses and explore expanded applications across other forms of field-ready medical equipment to improve readiness in both military and humanitarian contexts.
