3D Printed Cast With Venting Holes And Flexible Coating
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Solution Overview
Problem
Conventional rigid casts and splints are time-consuming to construct, inconsistent in sizing, lack breathability, irritate the skin, and are not adaptable to changes in patient anatomy or swelling, limiting their effectiveness in promoting healing and comfort.
Innovation Solution
A 3D printed, polymer-coated splint or cast with a custom-fit, waterproof, and washable design that incorporates a flexible inert polymeric coating to accommodate swelling and promote healing, featuring venting holes and adjustable engagement mechanisms for secure fit and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rigid casts and splints are constructed, then immobilization is provided, but construction time is excessive and consistency is poor
Solution Approach 1:
The patent applies 3D printing technology to transform the construction process from manual molding to automated additive manufacturing. This parameter change in the manufacturing method enables consistent reproduction of cast geometry while dramatically reducing construction time from hours to minutes.
Solution Approach 2:
The invention replaces the traditional mechanical system of manual cast application and molding with a digital 3D printing system. The digital model is directly translated into physical cast through additive manufacturing, eliminating the need for manual measurement, molding, and shaping operations.
2Adaptability or versatility
If conventional rigid casts are applied, then immobilization is achieved, but adaptability to anatomical changes is limited
Solution Approach 1:
The patent incorporates dynamic elements into the cast design, including adjustable components and flexible regions that allow the cast to adapt to changing anatomical conditions. The 3D printed structure can be designed with varying densities and flexibilities in different zones to accommodate swelling or atrophy while maintaining overall immobilization.
Solution Approach 2:
The cast is divided into multiple segments or zones with different properties. Some regions provide rigid immobilization while others offer flexibility or adjustability. This segmentation allows the cast to adapt to anatomical changes in specific areas without compromising the overall therapeutic function.
3Object-affected harmful factors
If conventional casts are constructed, then immobilization is provided, but breathability and skin comfort are poor
Solution Approach 1:
The 3D printed cast incorporates porous structures and ventilation channels that allow air circulation and moisture vapor transmission. This porous design reduces skin irritation and maceration while maintaining the mechanical strength and immobilization effectiveness of the cast.
Solution Approach 2:
The invention uses composite materials combining rigid 3D printed components with softer, more breathable materials. This composite construction provides both the necessary immobilization strength and the breathability required for skin comfort during extended wear.
4Adaptability or versatility
If conventional casts are applied, then immobilization is achieved, but waterproof capability is limited
Solution Approach 1:
The patent utilizes the parameters of 3D printing to create waterproof structures with integrated sealing features. The additive manufacturing process allows for precise control of wall thickness, overlapping joints, and integration of waterproof coatings or membranes, enabling the cast to function as a waterproof barrier while maintaining breathability through controlled porosity.
Data Source
AI summary
A 3D printed cast or splint for application to a patient's body to immobilize a body part includes first and second shell portions configured to conform to at least a portion of the body part. The first shell portion has a distal end, a proximal end, opposing interfacing edges, a plurality of venting holes and a first engagement mechanism positioned proximate one of the opposing interfacing edges. A reinforcement portion extends between the proximal and distal ends. The second shell portion has a distal end, a proximal end, opposing interfacing edges, a plurality of venting holes and a second engagement mechanism positioned proximate one of the opposing interfacing edges. The first engagement mechanism interacts with the second engagement mechanism in a mounted configuration to facilitate mounting of the first shell portion to the second shell portion.