From plaster to 3D printed splint: new project to improve immobilisation of forearm injuries

The emergency services of the Olot and Garrotxa Regional Hospital, the Campdevànol Hospital – Ripollès Regional Hospital, and the La Selva Regional Hospital (Blanes Hospital), have initiated a clinical trial to evaluate the impact of using 3D printed splints for immobilisation of distal radius fractures. In order to demonstrate that this technology offers a potentially superior alternative to the cast that is usually applied in emergency rooms when these forearm injuries occur, the three hospitals will test the new system until July 2025, and two months later, in September, they will share the results.  

The main aim of the study is to evaluate the impact, efficacy, efficiency and safety of the use of preformed IMUR® splints in distal radius fractures that patients who come to the emergency room present. Additionally, quality of life and clinical aspects related to distal radius fractures will be compared, the comfort of immobilisation will be evaluated, and the sustainability of the splint compared to plaster, the usability of the two immobilisation methods, and the time that professionals spend with the two immobilisation techniques will be analysed.

The project is driven by the Health Innovation Network of the Girona Regions, and coordinated by the TIC Salut Social Foundation and the Telecommunications and Information Technology Centre (CTTI).

Treatment of distal radius fractures

Distal radius fractures are one of the most common orthopaedic injuries, with a prevalence of between 25-30% in the adult population. In most cases, the recommended treatment is immobilisation of the injured area with plaster, because it provides stability to the fracture and allows the bone to heal properly.

Despite the benefits of the traditional plaster cast immobilisation technique, 20% of patients have complications resulting from poor plaster placement, such as skin lesions, compressive neuropathies and sympathetic-reflex dystrophy.

In recent years, with 3D printing techniques, splints for immobilisation of distal radius fractures made with biocompatible materials, such as polymer resins, have been developed. The use of this technology has potential benefits over plaster: it is more comfortable and lighter, has greater ventilation and ease of hygiene, better anatomical adaptation and a lower incidence of skin complications. In addition, it allows professionals to observe the affected area more easily, it does not produce hospital waste derived from the application of the plaster, and it can be sterilised and reused for other patients, among other advantages.

Next steps

From December 2024 to the end of July 2025, patients who arrive with this type of fracture in the emergency departments of the three hospitals participating in the study will be treated randomly with a cast or 3D splint, provided that they meet the inclusion criteria and sign the informed consent form. In this way, the professionals participating in the project will be able to compare and evaluate the benefits and disadvantages of both techniques.

The results of the study will be passed on to the Health System by assess its possible implementation, in the event that greater efficacy, efficiency, safety and sustainability of 3D splints are demonstrated compared with plaster. Likewise, a second phase is planned in which certain Primary Care Centres will be involved.