Randomized Controlled Trial of 3D-Printed Biodegradable Splints Versus Standard Casting in Upper-Limb Fracture Recover

Abstract

Background: Conventional plaster and fiberglass casts, though effective for immobilization, are often associated with discomfort, poor ventilation, and environmental waste. The advent of 3D-printing technology has enabled the development of biodegradable splints that can provide patient-specific support while addressing comfort and sustainability concerns.

Objective: To evaluate whether 3D-printed biodegradable splints improve comfort, healing rate, and functional recovery compared with standard casting methods in upper-limb fractures.

Methods: A randomized controlled trial was conducted in orthopedic departments across South Punjab, including 100 adult patients with closed, stable upper-limb fractures. Participants were randomly assigned to receive either 3D-printed biodegradable splints or standard casts. Comfort was assessed using a Visual Analog Scale (VAS), healing was evaluated radiographically, and function was measured using the Disabilities of the Arm, Shoulder, and Hand (DASH) score. Data were analyzed using independent t-tests, chi-square tests, and repeated-measures ANOVA, with significance set at p < 0.05.

Results: The mean comfort scores were significantly higher in the 3D-printed splint group at all follow-up intervals (Week 2: 8.1 ± 1.1 vs. 6.4 ± 1.3; Week 12: 8.9 ± 0.7 vs. 7.1 ± 1.0; p < 0.001). DASH scores improved more rapidly in the splint group (Week 12: 15.8 ± 4.2 vs. 21.4 ± 5.1; p < 0.001). Radiographic union rates at twelve weeks were comparable (94% vs. 88%; p = 0.32). Minor skin irritation occurred in 6% of splint users versus 18% of cast users.

Conclusion: 3D-printed biodegradable splints provided superior comfort, faster functional recovery, and comparable healing outcomes to standard casts, representing an effective, patient-centered, and sustainable alternative for upper-limb fracture management.