Craniocervical Orthosis Produced Using 3D Printing Technology for Anterior Head Tilt Posture and Thoracic Kyphosis: A...

Forward head posture (FHP) is common in young adults using technological devices and often accompanied by increased thoracic kyphosis. This study reports the design and custom manufacturing of a 3D-printed craniocervical orthosis and a pilot application evaluating its effects on the craniocervical angle (CVA), thoracic kyphosis angle (TKA), and user satisfaction. In this prospective, single-arm, within-subject pilot study, each participant underwent 3D scanning, and a custom orthosis was manufactured from their scan data using a common three-point CAD template via FDM 3D printing. Ten volunteers aged 18-25 years completed the study without a priori sample size calculation. The CVA and TKA were assessed photogrammetrically at baseline and weeks 2, 4, and 6, under orthosis-assisted and non-assisted conditions, with devices iteratively adjusted over six weeks. Satisfaction was evaluated at follow-up completion using the Quebec User Evaluation of Satisfaction with Assistive Technology (QUEST 2.0-TR), and data were analyzed using a linear mixed model. Of the 13 individuals screened, 10 completed the protocol (one discontinued owing to discomfort and two withdrew voluntarily); no serious adverse events occurred. The CVA was significantly higher, and the TKA significantly lower, under the orthosis condition at every time point (all p < 0.001), reflecting an acute, device-on effect rather than a demonstrated lasting, unassisted postural correction. Mean device satisfaction was 4.88 ± 0.12/5 and mean service satisfaction was 5.00 ± 0.00/5 among the 10 completers; these scores exclude the participant who discontinued owing to discomfort and two who withdrew for unrelated reasons, which likely inflates the apparent satisfaction level. The custom-manufactured orthosis was feasible to design and fabricate, tolerable after iterative adjustment, and associated with improved craniocervical and thoracic alignment when worn; these findings reflect an acute, device-on effect and do not yet establish lasting postural correction without the orthosis. Given the single-arm, non-blinded pilot design, findings are preliminary and hypothesis-generating, supporting further confirmatory trials.