3D Printed Arm Orthosis

Orthosis

A custom-designed medical device used to support, align, prevent, or correct deformities or to improve the function of movable body parts.

Problem Statement & Solution

You need an orthosis, or a splint when you have a broken bone or you have to limit your movement to prevent further injuries. But, not everyone around the world is able to rent or buy one even when they are in critical conditions, due to environmental factors such as financial constraints and limited access to healthcare facilities. Therefore, we designed an affordable yet functional arm orthosis for those in need. There are 3 sizes to choose from--Large, medium and small for people with different arm sizes.

1. Enclosed 3D printer
2. Filament(ABS or ASA)
3. 2 inches wide same-side Velcro straps(hook and loop strraps)

Dimensions(All with 90° joint)

Large: ≈296mm(11.6in.) x 138mm(5.4in.) x 198mm(7.8in.)

Medium: ≈300mm(11.8in.) x 118mm(4.6in.) x 192mm(7.6in.)

Small: ≈281mm(11in.) x 102mm(4in.) x 187mm(7.3in.)

Strength of the Filament

The joint part of the first prototype was bendable when pressure was applied.

We fixed this problem by making the joint part thicker, and connecting them to the adjacent parts.

Also, the thin part in the final prototype where the strap goes around broke several times after everything was glued together.

Failed Prints

The first prototype of the entire orthosis and second prototype failed due to the poor quality. (The quality of the first prototype was due to overhangs that are too long for almost all 3d printers to print)

We fixed this problem by making the part where it failed thicker, which was a natural thing to do while redesigning the whole prototype since everything was designed bigger than before.

Additional Notes

1. All parts are customizable, even though once they're glued together you can't change the parts.(not adjustable)
2. The designs are meant to be printed with strong filaments like carbon fiber or glass fiber filaments, although ABS was used for testing due to limited resources.
3. This Instructable was created originally for a science fair.