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This work proposes a digital methodology for producing patient-specific wrist immobilisation splint and evaluates form, fit and functional aspects of the fabricated splint by finite element analysis and post production performance testing. The upper limb of a volunteer is first scanned using a 3D scanner, then the data is reverse engineered to obtain a CAD model of the desired splint. Finally, A polyamide full-scale wrist splint is fabricated using selective laser sintering approach. Maximum von Mises stress and deflection developed during finite element analysis of CAD model are found 18.98 MPa and 0.68 mm respectively. The flexural and compressive strength of polyamide-PA2200 specimens have been found 67 MPa and 56 MPa respectively. In post production fitment test, splint is found conforming to anatomical shape, capable of providing adequate ventilation and performing intended task. Results show that the proposed methodology is technically feasible and has potential to be used as an alternative method of producing patient specific wrist immobilisation splint.

Patient-specific polyamide wrist splint using reverse engineering and selective laser sintering