Design, Manufacturing and Mechanical Evaluation of a 3D Printed Customized Wrist-Hand Orthosis for the Treatment of De Quervain Tenosynovitis †
by
, ,
Sofia Franco
1
Mauricio Ramos
1,
Renzo Cordova
1,
Emilio Ochoa
1
Gianella Ccama
1 and
Andoni Molina
2,*1
Sección Bioingeniería, Pontificia Universidad Católica del Perú, Lima 15088, Peru
2
CITE Materiales, Pontificia Universidad Católica del Perú, Lima 15088, Peru
*
Author to whom correspondence should be addressed.
†
Presented at the III International Congress on Technology and Innovation in Engineering and Computing, Lima, Peru, 20–24 November 2023.
Eng. Proc. 2025, 83(1), 2; https://doi.org/10.3390/engproc2025083002
Published: 6 January 2025
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Figure 1
<p>Solution concept.</p> "> Figure 2
<p>Area involved in immobilization [<a href="#B12-engproc-83-00002" class="html-bibr">12</a>]. A: Distal metacarpal area, B: Base of the thumb, C: Central Dorsal Area, D: Wrist Area, E: Distal palmar area.</p> "> Figure 3
<p>Autodesk Fusion 360: Selection of side of application of force (blue arrow).</p> "> Figure 4
<p>Manufacturing process of WHO.</p> "> Figure 5
<p>Mechanical test of WHO.</p> "> Figure 6
<p>Wrist movements, modified of [<a href="#B16-engproc-83-00002" class="html-bibr">16</a>]. (<b>A</b>) Flexion, (<b>B</b>) Extension, (<b>C</b>) Ulnar deviation and (<b>D</b>) Radial deviation.</p> "> Figure 7
<p>FTIR results.</p> "> Figure 8
<p>Manufacturing results: (<b>a</b>) Orthosis printed in 90° degrees. (<b>b</b>) Orthosis printed in 45° to the left. (<b>c</b>) Orthosis printed in 75° to the front.</p> ">
Versions Notes
<p>Solution concept.</p> "> Figure 2
<p>Area involved in immobilization [<a href="#B12-engproc-83-00002" class="html-bibr">12</a>]. A: Distal metacarpal area, B: Base of the thumb, C: Central Dorsal Area, D: Wrist Area, E: Distal palmar area.</p> "> Figure 3
<p>Autodesk Fusion 360: Selection of side of application of force (blue arrow).</p> "> Figure 4
<p>Manufacturing process of WHO.</p> "> Figure 5
<p>Mechanical test of WHO.</p> "> Figure 6
<p>Wrist movements, modified of [<a href="#B16-engproc-83-00002" class="html-bibr">16</a>]. (<b>A</b>) Flexion, (<b>B</b>) Extension, (<b>C</b>) Ulnar deviation and (<b>D</b>) Radial deviation.</p> "> Figure 7
<p>FTIR results.</p> "> Figure 8
<p>Manufacturing results: (<b>a</b>) Orthosis printed in 90° degrees. (<b>b</b>) Orthosis printed in 45° to the left. (<b>c</b>) Orthosis printed in 75° to the front.</p> ">
Abstract
:De Quervain’s tenosynovitis is a pathology that affects the tendons of the thumb and generates pain and inflammation, being common in people between 18 and 30 years old who perform repetitive movements. Despite the innovation of 3D printing in orthotics, customization is lacking. Therefore, this works aims to develop a 3D printed customized wrist-hand orthosis (WHO) for the treatment of De Quervain tenosynovitis. The WHO includes three main parts, which would be two faces that cover the front and back of the hand and the locks to ensure the coupling of both faces. Prior to 3D printing, feedstock filament characterization tests were carried out, and tensile strength, melt flow index, degradation, and melting temperature were obtained. 3D printing of the WHO was achieved in a short time and with an adequate fit. Subsequently, mechanical tests were carried out to evaluate the maximum force of the WHO in different positions.
1. Introduction
De Quervain’s tenosynovitis is a pathology that affects the fibrous sheath that surrounds the tendons of the abductor pollicis longus and the extensor pollicis brevis [1]. It is characterized by a thickening of the extensor retinaculum of the tendons, which generates pain and inflammation at the base of the thumb, causing difficulty in the movement of the wrist [2]. The cause of this disease is not defined, but it is estimated that it originates due to repetitive hand movements and excessive use [2,3]. The worldwide incidence of the pathology is 0.28 to 3 cases per 1000 people per year and in Latin America the prevalence is between 5–13% of the total population [4].
The treatment of De Quervain’s tenosynovitis involves various methods. These are divided into pharmacological treatment, which focuses on the use of anti-inflammatories and analgesics; physiotherapy, which focuses on thermal and/or electrical (ultrasound) treatment and massage of the affected area; and orthopedic treatment, which is based on the use of immobilizing splints for four weeks day and night, and two additional weeks only at night [5]. Comparative studies between the various treatments determine that the use of an orthosis/splint that helps immobilize the affected area generates a considerable improvement compared to the other treatments individually [4]. It is advisable to continue with orthopedic treatment at the same time as other treatment alternatives to guarantee a quick recovery [6,7]. Hand-wrist orthoses are commonly manufactured from low-temperature thermoplastic (LTTP) materials. These require continuous care to avoid complications such as skin irritation and harmful perspiration odors. In addition, they tend to be bulky and cumbersome, causing discomfort to the patient [8,9].
3D printing is a manufacturing technique for layer-by-layer deposition of polymeric materials for the construction of structures modeled in 3D design software. This technique allows the rapid manufacturing of personalized objects with complex structures and with a reduction in manufacturing prices [10]. There is no specific orthosis (3D printed) for the pathology we are describing. Furthermore, due to the need to save material and enhance manufacturing speed, commercially printed orthoses are general purpose, that is, without specificity in size and shape. Therefore, the orthoses generated are not customizable to the anthropometric measurements of a desired patient, which causes treatment discomfort.
An analysis of the state of the art is carried out to establish a basis on which to implement our orthosis. To do this, commercial devices are analyzed to determine the price and size standards, and patents in which the 3D printing technique was used. Commercial orthoses are commonly manufactured with thermoplastic or elastomeric materials (neoprene), with standard sizes (S, M, L, XL) and with a price that approaches 150 PEN. The patent ’US10758396B2’ consists of a two-part 3D printed splint with surface ventilation holes and attachment systems. The design guarantees immobilization of the affected area in an adaptable and ventilated manner [11]. Therefore, this works aims to develop a 3D printed customized wrist-hand orthosis (WHO) for the treatment of De Quervain tenosynovitis to improve the current orthopedic treatments.
2. Materials and Methods
In this section, solution concept, material and characterization, design of WHO, manufacturing process, and mechanical tests are described in detail.
2.1. Solution Concept
The solution concept is a wrist immobilizing orthosis for patients with de Quervain’s tenosynovitis that is personalized and 3D printed. See Figure 1 as a guide.
The main function of the orthosis is to limit the mobility of the affected area. It should be maintained in a position of 35–40° of extension and a slight ulnar deviation of 10°, allowing metacarpophalangeal mobility of all fingers [12].
The area involved is divided, starting with the distal area, which is limited by the metacarpal heads. At the base of the thumb, the edge is proximal to the metacarpophalangeal joint, limiting the movement of the base of the thumb, but not the other fingers. On the palmar aspect, the edge is distal to the distal palmar crease so as not to interfere with the movement of the fingers. See Figure 2 as guide.
2.2. Material and Characterization
The material used to manufacture the orthosis is polyethylene terephthalate glycol-modified (PETG) in filament form of Ø1.75 mm. PET-G is a semicrystalline thermoplastic copolymer widely used in 3D printing; Glycol (letter G in its name) gives it greater flexibility and resistance [13]. The properties of PETG and its comparison with the most common polymers in 3D printing (PLA and ABS) are shown in Table 1. Characterization tests were performed to determine the properties of the PETG filament as detailed in the following subsections.
2.2.1. Tensile Test of PETG Filaments
The tensile test consists of applying an axial force at a constant speed to one end of the sample with known cross-sectional area dimensions, while the other end is held in a fixed position (clamp). The objective of the test is to determine the tensile strength and Young’s modulus of the PETG filaments. A Zwick/Roell Z050 with a load cell of 1 kN was used with an extensometer.
2.2.2. Fourier-Transform Infrared Spectroscopy (FTIR)
FTIR measures the interaction of infrared radiation with the PETG sample. Molecules absorb specific wavelengths that are represented as vibrations in bonds. The FTIR test enables identification of the chemical composition of the material, facilitating an evaluation of its compatibility and overall quality. The equipment used to carry out the test was Bruker Tensor 27 (Bruker Optik GmbH, Ettlingen, Germany).
2.2.3. Differential Scanning Calorimetry (DSC)
In DSC, the flow of energy transmitted between the material of interest and a reference material (crucible) is measured. The heat flow is generated by increasing and decreasing the temperature of the system, identifying the endothermic and exothermic variations of the PETG. The objective of this test is to identify the melting temperature and the glass transition temperature, important parameters when printing the material. The DSC essay was performed in three stages. The first stage is to increase the system temperature from 0° to 300° to eliminate thermal memory. The second stage consists of cooling the system from 300° to 25° to begin with the last stage, having already eliminated the thermal memory. The last stage consists of increasing the temperature from 25° to 300° to obtain the transition peaks that we wish to evaluate.
2.3. Design of WHO
The orthosis is slated for manufacturing via a single-piece 3D scanning and additive manufacturing process, incorporating side joints for placement convenience. Additionally, the design entails ventilation holes shaped as regular hexagons, each measuring 1 cm per side. This shape and location were chosen according to the force simulations carried out in the Autodesk Fusion 360 software v.2.0.14344.
2.4. Manufacturing Process
The manufacturing process is described in Figure 4 by the next step: 3D scan, mesh editing, piece editing, slicer, and 3D printing.
The Sense 3D device is employed for scanning our patient’s hand. MeshMixer software v.3.5 is used for implementing essential cuts and corrections, ultimately deriving the shell of the hand, which forms the orthosis. Piece editing (3D model) was performed in Autodesk Inventor software v.2023.5.2 to create ventilation holes, joints, and securing hooks for the part. The Slicer software was Ultimaker Cura v.5.5, converting the 3D model into code interpretable by a 3D printer. The 3D printing of WHO was perform utilizing an Artillery Sidewinder X3 printer (Artillery3d, Shenzhen, China). The setting of 3D printing process parameters is shown in Table 2. This results in a printing time of 21 h, with an approximate consumption of 120 g of filament.
2.5. Mechanical Tests of WHO
The feasibility of the orthosis to guarantee immobilizing functionality is evaluated by a two-point bending test. To carry out the test, a stainless-steel plate is manufactured into which the orthosis is fitted using a support module previously printed with the ideal surface that allows the exact connection with the orthosis. A punch applies a force at 5 mm/s until a break is evident. In this way, the maximum load that the orthosis can withstand until breaking is obtained. The equipment used is the Zwick/Roell Z050 (ZwickRoell GmbH, Ulm, Germany), as shown in Figure 5.
The first evaluation is performed with the goal of establishing an appropriate 3D printing orientation of the orthosis. To do this, three orthoses are tested at different 3D printing orientations, 45°, 75° and 90°, and it is determined as to which one supports the greatest load prior to rupture.
Once the proper 3D printing orientation is obtained, four bending tests are performed to simulate the four hand/wrist movements. To do this, the orthosis is placed in the support module in the orientation corresponding to the four movements and the point force is applied. See Figure 6.
3. Results and Discussion
This section evaluates the results obtained from the various tests performed to ensure the functionality of the material and validate the purpose of the orthosis.
3.1. Material Characteriztion
3.1.1. Tensile Test
Thirty-three tensile tests were carried out on thirty-three samples with the same cross-sectional area. The average of each mechanical property obtained from all samples is shown in Table 3.
The results obtained show a large Young’s modulus value, which implies great material rigidity [17]. Additionally, the breaking strength of 45.17 MPa ensures that the material can withstand a large amount of stress before breaking. Both characteristics establish PETG as an ideal material for manufacturing an immobilizing orthosis.
3.1.2. FTIR
The spectrum obtained from the FTIR test is shown in Figure 7. A stretching of the Carbon—Hydrogen bond can be observed at the common PETG wavelength 2928 cm−1. The Benzene ring of PETG is evident at the wavelength of 792 cm−1. In this way, it is verified that the material analyzed is PETG. The results and interpretation are shown in Table 4.
3.1.3. DSC
The glass transition is obtained at 80°. The glass transition at this temperature indicates the semi-crystalline nature of the material, an important property to be able to print since the material needs to be brought to its amorphous state. Furthermore, the melting point is generated at approximately 230°. The melting point at this temperature provides us with an initial limit to be able to print the material. This way, we can choose the appropriate printing temperature.
3.2. Manufacturing Results
3.3. Mechanical Tests
The results obtained in the first evaluation are shown in Table 6, where the orientation can be established at 90° as the optimal one for 3D printing
Table 7 corresponds to the results obtained in the second evaluation. The results guarantee the stability of the orthosis by recreating the four rotations of the wrist and verifying that the results obtained exceed the limit of the forces generated by the movements. The range of force exerted by the four movements of the wrist varies between 0.50–10.61 Nm for the flexion movement, 0.50–9.60 Nm for the extension movement, 1.01–14.60 Nm for the ulnar movement, and 0.69–11.81 Nm for the radial movement [18].
4. Conclusions
Successful 3D printing of a WHO orthosis was achieved using 3D printing with PETG in a single articulated piece. This allows us to reduce material costs and manufacturing time, thereby fulfilling our goal of improving conventional orthopedic treatment. The choice of PETG as the printing material was validated by the characterization tests in which suitable mechanical properties were obtained to guarantee rigidity; in addition, the thermal analysis did not show the semi-crystalline nature of the material and gave us the printing temperature at 232 °C. Likewise, the mechanical test allowed us to establish the appropriate printing orientation to generate greater resistance in the orthosis (90°) with values of 41.54 kgf for flexion, 22.19 kgf for extension, 24.05 kgf for ulnar rotation, and 35.21 kgf for radial rotation. In summary, we conclude that additive manufacturing is a consolidated technique with incredible potential in orthopedic treatments.
Author Contributions
All authors contributed equally to this work. All authors have read and agreed to the published version of the manuscript.
Funding
This research received no external funding.
Institutional Review Board Statement
Not applicable.
Informed Consent Statement
Not applicable.
Data Availability Statement
All data produced in this study are included in the paper.
Acknowledgments
The authors would like to thank Core Facilities—FABCORE from Pontificia Universidad Católica del Perú.
Conflicts of Interest
The authors declare no conflicts of interest.
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Figure 1.
Solution concept.
Figure 2.
Area involved in immobilization [12]. A: Distal metacarpal area, B: Base of the thumb, C: Central Dorsal Area, D: Wrist Area, E: Distal palmar area.
Figure 2.
Area involved in immobilization [12]. A: Distal metacarpal area, B: Base of the thumb, C: Central Dorsal Area, D: Wrist Area, E: Distal palmar area.
Figure 3.
Autodesk Fusion 360: Selection of side of application of force (blue arrow).
Figure 4.
Manufacturing process of WHO.
Figure 5.
Mechanical test of WHO.
Figure 6.
Wrist movements, modified of [16]. (A) Flexion, (B) Extension, (C) Ulnar deviation and (D) Radial deviation.
Figure 6.
Wrist movements, modified of [16]. (A) Flexion, (B) Extension, (C) Ulnar deviation and (D) Radial deviation.
Figure 7.
FTIR results.
Figure 8.
Manufacturing results: (a) Orthosis printed in 90° degrees. (b) Orthosis printed in 45° to the left. (c) Orthosis printed in 75° to the front.
Figure 8.
Manufacturing results: (a) Orthosis printed in 90° degrees. (b) Orthosis printed in 45° to the left. (c) Orthosis printed in 75° to the front.
Table 1.
PETG properties and its comparison with PLA and ABS (Author’s own compilation) [14].
Table 1.
PETG properties and its comparison with PLA and ABS (Author’s own compilation) [14].
| PETG | PETG vs. PLA | PETG vs. ABS |
|---|---|---|
| Resistance and durability | Greater flexibility | Greater ease of printing |
| Glass-like transparency | and mechanical resistance | (lower printing temperature) |
| UV resistance | ||
| Recyclable material | ||
| Waterproof Material | ||
Table 2.
Values of the 3D printing process parameters.
| Parameter | Unit | Value |
|---|---|---|
| Layer height | mm | 0.2 |
| Nozzle temperature | °C | 232 |
| Printing speed | mm/s | 40 |
| Walls | Lines | 3 |
| Infill | % | 5 |
Table 3.
Mechanical properties of PETG filaments.
| Mechanical Properties | Value | Std. Dev | Unit |
|---|---|---|---|
| Young’s modulus | 1900 | 128 | MPa |
| Tensile strength | 44.2 | 8.3 | MPa |
Table 4.
Functional groups and characteristic wavelength.
| Wavelength (cm−1) | Possible Assignment |
|---|---|
| 2927–2854 | C-H stretching (methylene and methyl) |
| 11714 | C=O stretching (ester) |
| 1407 | CH2 flexion |
| 1241 | Ester group |
| 792 | Benzene ring |
Table 5.
Manufacturing results.
| Inclination | 90° | 45° | 75° |
|---|---|---|---|
| Printing time | 21:44 h | 24:10 h | 22:05 h |
| Material consumed | 142.8 g | 144.6 g | 143.2 g |
Table 6.
Maximum forces for different 3D printing orientation of WHO.
| 3D Printing Orientation | Force (N) | Force (kgf) |
|---|---|---|
| 75° | 344.7 | 35.1 |
| 45° | 399.0 | 40.7 |
| 90° | 407.5 | 41.5 |
Table 7.
Maximum forces for four different positions of WHO.
| Movement | Force (N) | Force (kgf) |
|---|---|---|
| Flexion | 407.5 | 41.5 |
| Extension | 217.7 | 22.2 |
| Ulnar | 235.9 | 24.1 |
| Radial | 345.5 | 35.2 |
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MDPI and ACS Style
Franco, S.; Ramos, M.; Cordova, R.; Ochoa, E.; Ccama, G.; Molina, A. Design, Manufacturing and Mechanical Evaluation of a 3D Printed Customized Wrist-Hand Orthosis for the Treatment of De Quervain Tenosynovitis. Eng. Proc. 2025, 83, 2. https://doi.org/10.3390/engproc2025083002
AMA Style
Franco S, Ramos M, Cordova R, Ochoa E, Ccama G, Molina A. Design, Manufacturing and Mechanical Evaluation of a 3D Printed Customized Wrist-Hand Orthosis for the Treatment of De Quervain Tenosynovitis. Engineering Proceedings. 2025; 83(1):2. https://doi.org/10.3390/engproc2025083002
Chicago/Turabian StyleFranco, Sofia, Mauricio Ramos, Renzo Cordova, Emilio Ochoa, Gianella Ccama, and Andoni Molina. 2025. "Design, Manufacturing and Mechanical Evaluation of a 3D Printed Customized Wrist-Hand Orthosis for the Treatment of De Quervain Tenosynovitis" Engineering Proceedings 83, no. 1: 2. https://doi.org/10.3390/engproc2025083002
APA StyleFranco, S., Ramos, M., Cordova, R., Ochoa, E., Ccama, G., & Molina, A. (2025). Design, Manufacturing and Mechanical Evaluation of a 3D Printed Customized Wrist-Hand Orthosis for the Treatment of De Quervain Tenosynovitis. Engineering Proceedings, 83(1), 2. https://doi.org/10.3390/engproc2025083002