Using 3D Printing & 3D Scanning to Replace Traditional Casts

3D scanning and 3D printing are reshaping orthopedic immobilization. Instead of traditional POP or even some fiberglass casting tape use-cases, clinicians can capture limb geometry, design a ventilated lattice cast, and 3D print a patient-specific device. The result: improved fit, airflow, and a more modern care experience. This article outlines the workflow, benefits, limitations, and how to choose between traditional and printed solutions.

Digital Workflow: From Scan to Finished Cast

• 3D Scan: capture full limb with a handheld/optical scanner; include joints and edge zones clearly.
• CAD Design: smooth the mesh, set thickness, lattice pattern, and reinforcements; release pressure-prone areas.
• 3D Printing: common materials include PA12, TPU, or engineered resins; choose by strength, weight, biocompatibility, and finish.
• Fit & Finish: test on-limb, deburr edges, mount closures, and provide patient instructions.

Advantages over Traditional Bandaging

• Ventilation & hygiene: lattice geometry reduces sweating, itching, and skin issues.
• Fit & comfort: customized design reduces pressure points and overall weight.
• Openable designs: two-piece casts can be opened for checks or physio.
• Aesthetics & acceptance: modern look encourages adherence.
• Repeatability: digital files enable redesign and reprint when needed.

Challenges & Considerations

• Time & cost: scanning, CAD, and printing add lead time and expense.
• Standards & durability: mechanical/biocompatibility testing, moisture/UV resistance, safe edges.
• Clinical indications: not all fractures suit printed casts—final call rests with the clinician.
• Service model: trained CAD/CAM team and disinfection protocol for printed hardware.

When Fiberglass Still Wins

• Emergencies prioritizing speed, availability, and lower cost.
• Temporary casts that need quick adjustments or stepwise re-evaluation.
• Standardized, widely proven workflows less sensitive to digital steps.

How to Choose Between Options

• Fracture/surgical profile: stability needs, immobilization duration, skin-pressure sensitivity.
• Access & timeline: availability of scanning/printing and turnaround.
• Budget/coverage: reimbursement and total cost of care.
• Patient preference: hygiene, lifestyle, occupational needs.

Conclusion & CTA

3D technologies open new horizons for custom casts, yet fiberglass casts remain advantageous in many routine and urgent scenarios. For case-by-case evaluation and choosing the right path (traditional vs. printed), contact us.