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A study evaluated the economic aspects of the manufacturing of 3D-printed hand orthoses compared to conventional low-temperature thermoplastic orthoses, revealing a nuanced cost landscape for both approaches. Researchers identified that while the initial financial outlay for establishing a reliable 3D-printing operation—such as investment in advanced printing hardware, specialized software, and staff training—may present a significant hurdle for clinics and health systems, there are compelling advantages driving future adoption. Specifically, the study highlighted the lower material costs and reduction in production waste associated with 3D printing, which could contribute to cost savings over time, especially as processes are scaled up. Furthermore, advancements in 3D printing technology and increased utilization of the infrastructure have the potential to drive down both per-unit and upfront investment costs, increasing the feasibility of broader clinical implementation.
The researchers conducted a prospective cost minimization analysis from the perspective of a healthcare provider, comparing the production of eight custom-fitted 3D-printed hand orthoses with nine low-temperature thermoplastic orthoses fabricated using traditional molding techniques. Their analysis showed that, on average, the total cost per orthosis was higher for the 3D-printed devices (€46.54 or $54.49 USD) than for thermoplastic alternatives (€30.28 or $35.45 USD). A breakdown of the specific expenditures revealed that the dominant costs associated with 3D printing were attributable to labor, which constituted 62.2 percent of the expense, and the initial purchase of specialized equipment and supplies, accounting for 22.2 percent. For low-temperature thermoplastic orthoses, costs were primarily driven by material (69.4 percent) and labor (30.6 percent).
Manufacturing of the 3D-printed orthoses commenced with the therapist scanning the affected limb during the patient’s first visit, utilizing an optical structure sensor (Mark I Structure Sensor, Occipital Inc.) attached to a tablet. Next, a CE-marked application (Spentys Point-of-Care Solution) enabled the design of a customized orthosis via semi-automated 3D modeling based on the acquired anatomical data. The digital model was exported as a Standard Tessellation Language (STL) file, which was then fabricated using in-house Digital Light Processing (DLP) technology and photosensitive resin (BASF Ultracur3D, ST45B, black).
Upon completion of the printing process, the orthosis underwent multiple post-processing steps to ensure functionality and safety. This included manual wiping with ethanol to remove residual resin, curing under ultraviolet light in a vacuum chamber (atum3D Curing Station; atum3D), removal of support structures, and meticulous sanding to smooth edges. At the patient’s second appointment, the orthosis was custom-fitted and secured with Velcro straps. All stages were carried out by skilled hand therapists, with direct active labor averaging 45 minutes per device, while the actual printing lasted approximately 11 hours.
In contrast, the production of low-temperature thermoplastic orthoses followed more traditional, hands-on methods that required less technological investment. The therapist began by outlining a pattern of the device on plastic foil, using the patient’s hand and arm as templates for a precise fit. The selected thermoplastic sheet (Klarity KS 3.2 mm, Klarity Medical & Equipment Co.) was cut to shape, then briefly heated in a water bath (WDB 6-100/4; Heuser Apparatebau) at 70 degrees Celsius. Malleable and soft, the thermoplastic material was molded directly to the patient’s forearm and hand. Final adjustments involved trimming overlapping areas, smoothing and correcting edges using a heat gun, and affixing the Velcro straps. The entire manufacturing process for these orthoses was typically completed in a single therapy session, with an active time averaging just 14 minutes.
The open-access study, “Economic evaluation of the manufacturing of 3D-printed wrist orthoses vs. low temperature thermoplastic wrist orthoses,” was published in 3D Printing in Medicine.
