Material Matters: A Comparative Analysis of Hand Immobilization Orthoses Using 3D-Printed, Thermoplastic, and Fiberglass Cast

Background: Orthosis fabrication is a widely used technique in occupational therapy, and there is growing evidence supporting the use of 3D printing in the fabrication of cost-effective orthotics. Nevertheless, further research is needed to enable informed decision-making when selecting appropriate orthotic materials. Method: A comparative analysis was conducted to evaluate the fabrication processes and final products of thumb immobilization orthosis made with three different materials from the fabricator's perspective. Factors examined included the required equipment and materials, assessment of time and skills involved in the fabrication process, evaluation of ease of adjustment during fabrication, and objective measurements of functional outcomes. Results: Among the different orthosis materials evaluated, the 3D-printed orthotic demonstrated the highest level of cost-effectiveness and replicability. However, it was also found to be the most time-consuming to fabricate, requiring a significant learning commitment and initial investment. Conclusion: Thermoplastic may be better suited for functional orthoses, while fiberglass cast may be more appropriate for short-term and non-functional orthoses. It is crucial for fabricators to have a comprehensive understanding of orthotic materials and their properties to select the most suitable option based on the user's specific condition and occupational requirements. Comments The authors declare that they have no competing financial, professional, or personal interest that might have influenced the performance or presentation of the work described in this manuscript. Keywords orthosis thermoplastic, 3D-printed, fiberglass cast, splint material, hand therapy