Development and Analysis of Three-Dimensional Printed Hand Cast: Finite Element and Comfortability Analysis

Bone fracture treatment aims for restoring the function of a broken bone, and for scaphoid fracture, the conventional cast is an example of commonly used treatment. However, due to its downsides, the development of customized three-dimensional (3D) printed hand cast is getting more attention. It is lightweight, easy to manage, has good ventilation and hygienic properties. Hence, this study aims to fabricate customized 3D printed hand cast in treating scaphoid fracture. Three designs were made and analysed accordingly based on three different tests, including Finite Element Analysis (FEA), comfortability, and clinical effectiveness test. Design 2 was chosen as the best design as it produced lower stress and displacement in FEA and higher total mean score for clinical effectiveness. In conclusion, the fabricated casts were proven to help in restoring the broken bone besides providing comfort to the patient.