Current perspectives on 3D-printed casts

Aim: Fractures of the distal radius and ulna are among the most common skeletal injuries and are traditionally treated with cast immobilization. However, conventional casting techniques have significant limitations. In recent years, three-dimensional (3D) printing technology has emerged as a promising alternative in the production of personalized post-traumatic stabilization devices. The aim of this review was to present current information and perspectives on the development of 3D-printed casts, with particular emphasis on the diversity of designs, material properties, and clinical applications.

Materials and Methods: A literature review was conducted using the PubMed and Google Scholar databases. The results of the analyzed studies indicate that additive technologies enable the production of lightweight, ventilated, individually tailored orthoses with high mechanical strength and improved moisture resistance compared to traditional casts and glass fiber casts.

Conclusions: Materials such as polylactide (PLA) and PLA composites produced by Fused Filament Fabrication (FFF) demonstrate superior properties in static and dynamic tests. Furthermore, 3D-printed casts offer improved hygiene, greater comfort, a reduced risk of skin complications, such as wound healing, and high aesthetic acceptability. Clinical applications also include planning corrective osteotomies and the production of personalized surgical instruments. Although further research is needed on long-term durability and broad clinical outcomes, current reports indicate that 3D printing is a promising and increasingly viable alternative to traditional cast immobilization.