Oct. 4, 2014 | By Alec

We already knew that 3D printing technology was an excellent option for replacing old-fashioned casts and prosthetics, as they offer new levels of customization that can suit anyone's needs. We therefore already seen a variety of examples pass along, like the #Cast and the Cortex Cast, while E-NABLE is doing wonderful work developing custom prosthetics.

However, why outsource it, if you can construct your own using a regular desktop extrusion 3D printer? Fortunately, the Italian design team behind LAB+ has released designs for this on Thingiverse. Check out their wrist brace here.

While not the first to do so, they are using an ingenious way to overcome the most common problem that 3D printing custom-fitted objects have. How do you make it fit properly without wasting an endless stream of material on half a dozen prototypes? But with their design, you only need to print a single wrist brace in PLA material and easily make it fit.

Firstly, however, they rightly warn you: 'We are not doctors (just designers) so we recommend to test any design with your physiotherapist, and to adapt the design to your needs and your size.'

Borrowing an ingenious (but simple) concept from designer Andreas Bastian, they print out a flat design of the brace, and then give it its proper shape by heating it up to 60 degrees Celsius – at which temperature PLA material becomes malleable – and shaping it on your wrist.

Andreas Bastian shares a number of methods with which this can be achieved:

1. Toaster oven. This method is my favorite because it keeps the gauntlet dry and it is easier to handle without being covered in hot water. Set the toaster oven to a medium heat (200-300 F) and check frequently with a fork for flexibility and softness.

2. Hot air gun/hair dryer. It's a little trickier to get even heating using forced hot air, but a hair dryer is very useful for tweaking the fit and re-working the form to get a perfect fit.

3. Microwave with water. As PLA does not convert microwaves to heat very well, it is necessary to submerge it in a shallow bowl or plate of water to heat it. Microwave until the water is boiling and then remove with a fork or tongs when soft.

Afterwards, the PLA material will stay malleable for about a minute, after which it will start to stiffen up again. This way, you have a reasonable window to form the wrist brace to its desired shape, while you can easily re-heat it if you're not quite happy with the results.

However, this ingenious method comes with just a single point of caution: while PLA filament is non-toxic, it has not been tested as rigorously as medical-grade materials are. It is therefore unclear what long-term exposure to PLA will do to your health, so Bastian recommends using a 'wrist sock' underneath the brace to avoid direct skin contact.

Aside from that one point, however, both the forming method and the easy design that +LAB has come up with are ingenious innovations that highlight the innovative strength of the Maker community.

+LAB is an innovative studio of Italian designers and 3D printing enthusiasts with links to the Politechnical University of Milan, that has an extensive Chemicals and Engineering deparment. The team works towards the very noble aim of diffusing '3D Printing culture from academies to society: we truly believe that this technology and its customizability features can have real influences in many aspects of our everyday life.' This is reflected in their open-source approach to technology and 3D designs. They also teach a variety of workshops where people can become familiar with the potential of 3D printing technology.

 

 


Posted in 3D Printing Services

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Juan Monzón wrote at 10/7/2014 12:01:44 PM:

exovite is doing 3d printer splints too.

3dprintrihaz wrote at 10/5/2014 6:47:17 AM:

You that this was on thingiverse since atleast mid summer. Why are you so late?

James wrote at 10/4/2014 6:42:53 PM:

Alec, how can I get ahold of you for a story I have?



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