Custom 3D-Printed Orthosis from 3D Scan for a Child’s Hand (Left Hand)

A child fractured a finger on their left hand, but the traditional plaster cast became wet and failed. I was nearby and able to help immediately. I scanned the child’s left hand in the correct anatomical position using a handheld 3D scanner. The scan data was then processed in DesignX software to create a precise 3D model of the hand and finger geometry. Based on the scan, I designed a custom orthosis (splint) that perfectly fits the hand, immobilises the injured fingers, and provides the required support. The orthosis was 3D printed using FDM technology, ensuring it is lightweight, breathable, and comfortable for the child to wear. This project demonstrates the ability to combine 3D scanning, reverse engineering, and 3D printing to solve real-world medical and rehabilitation challenges quickly and effectively.