Novel PLA-CaCO3 composites in additive manufacturing of upper limb casts and orthotics—A feasibility study

Additive manufacturing technologies provide rapidly developing and promising solutions in many fields of healthcare. Traumatic upper limb injuries are among the most common conditions worldwide. In the case of a traumatic bone fractures it is crucial to provide immobilisation of the affected limb in the correct anatomical position to achieve the desirable healing process. Thus, splints and casts play an essential role in the healing and rehabilitation progress. 3D printing is a powerful tool in creating personalized biomedical devices, therefore, medical aids for the treatment of bone fractures are amongst the most promising fields of medical 3D printing. In medical care, the most extensively used area of additive manufacturing is Fused-Filament-Fabrication (FFF). In our study we have investigated two different unique PLA-CaCO3 composites. To access the characteristics of the composites, dynamic and static mechanical stability tests were performed along with scanning electron microscopy for the structural analysis, and also manufactured splints with the help of 3D design and thermoforming methods. According to our results the new materials are potentially viable in clinical environment, but further laboratory and clinical investigations are necessary. Our aim is to continue the feasibility tests and establish the appropriate clinical trials.