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Personalized 3D-Printed Finger Splints Derived from CT Data Incorporating Multi-Drug Bilayer Nanofiber Delivery

Ahmed M Mortada1, Alaa Y Darwesh1,2, Iman E Taha3

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Summary
This summary is machine-generated.

This study introduces personalized 3D-printed finger splints for enhanced fracture healing. The splints deliver anti-inflammatory hydrocortisone and analgesic ibuprofen directly to the injury site, improving patient recovery.

Keywords:
3D printingfinger fracturesmedical Imagingnanofiber drug deliverypersonalized splint

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Area of Science:

  • Biomaterials Engineering
  • Musculoskeletal Injury Management
  • Drug Delivery Systems

Background:

  • Conventional finger splints offer suboptimal fit and localized support, potentially delaying healing and increasing complications for common finger fractures.
  • There is a need for advanced splinting solutions that provide targeted therapeutic delivery alongside structural support.

Purpose of the Study:

  • To develop and evaluate a patient-specific, 3D-printed finger splint with integrated localized dual drug delivery capabilities.
  • To provide concurrent anti-inflammatory and analgesic therapy using hydrocortisone and ibuprofen for improved fracture management.

Main Methods:

  • Computed tomography (CT) data were used to design patient-specific splints fabricated via fused deposition modeling (FDM) and stereolithography (SLA).
  • A bilayer electrospun nanofiber mat (polycaprolactone for ibuprofen, pullulan for hydrocortisone) was coated onto the splint's inner surface.
  • Drug entrapment, release kinetics, and ex vivo skin permeation were comprehensively characterized.

Main Results:

  • The 3D-printed splints featured a rigid outer shell and flexible inner layer with high drug entrapment efficiencies (>90%).
  • In vitro studies showed rapid release of hydrocortisone (79.68% in 2h) and sustained release of ibuprofen (51.75% in 24h).
  • Ex vivo permeation studies demonstrated significantly enhanced delivery of both drugs compared to controls.

Conclusions:

  • CT-guided, personalized 3D-printed finger splints effectively integrate structural support with localized multidrug delivery.
  • This innovative approach offers a promising platform for next-generation, patient-tailored fracture management, enhancing therapeutic outcomes.