3D Printed Casts are the Next Big Thing

Breaking your arm is never fun. Wearing a cast is even worse. It is almost like they are designed to be uncomfortable. They’re bulky and cumbersome and they weigh a ton. That’s where 3D printing comes into the picture. 3D printing is trying to make plaster and fiberglass casts a thing of the past.

The nature of 3D printing makes the scenario of broken bones less of a hassle.The 3D printed cast can be adjusted in terms of shape and size to tailor-fit the patient. The design is set to support only in the areas needed, so the cast does not need to envelope your entire limb. That means less weight and less discomfort. And in the looks department, you can definitely say it's more attractive than a plaster cast.

Don't expect to get your cast 3D printed quite yet though. Because it is still relatively new, the process can be more expensive dollar-wise. Despite the price tag, you at least save on materials (as you don't cover the entire limb) and you save on time (because it is easier to put on and remove compared to a plaster cast). The material used for the cast is not difficult to find either: It’s very similar to 3D printer filaments used in your regular 3D printer.

3D Systems is in the business of making 3D printed things. A prosthetics company called Bespoke decided to team up with them and give this a try. The collaboration began when Scott Summit (a director in 3D Systems) broke his arm. The two companies came up with a design with inputs from an orthopedic surgeon so that it would still be able to support the broken bones as they heal. The cast they created with did not need as much material so it was much more comfortable to wear long-term. There wasn't a need to keep it dry since the 3D printed cast was made of plastic .It even allowed the flexibility of applying hot or cold compresses directly onto the skin as needed because the entire arm was not covered.

Mike North also came up with his own 3D printed cast when he broke his own leg. North did not want to use conventional cast designs that would limit his active lifestyle. Instead, he teamed up with Fathom Studio (a 3D printing company) and used additive manufacturing to create a custom fitted cast strong enough to support his bone healing but at the same time light enough to provide easy mobility. At the same time to promote healing, sensors were also added to the cast. Data from the sensors was fed to North's doctor to track leg swelling and current leg movement.

With the development of 3D printing, you really cannot identify a lone area of growth.  As soon as the technology emerged, all industries started to leverage on the possibilities it could deliver, from defense, automobile and aerospace to fine arts and fashion. Clearly, the medical manufacturing arena is no exception to this rule.