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VIDEO DOI: https://doi.org/10.48448/xr1w-0887

poster

AMA Research Challenge 2024

November 07, 2024

Virtual only, United States

Systematic Review and Novel Proposal of 3D-Printed Casting for Non-Surgical Treatment of Acute Achilles Tendon Rupture

Background: Achilles tendon rupture is a common orthopedic injury presenting to the clinic and emergency room. Patients with comorbidities are not ideal surgical candidates and often must be treated with cast or boot immobilization. The risk of complications includes pressure sores, skin infections, and joint stiffness. Recently, 3D-printed (3DP) casting has become popular due to customizability and inexpensiveness. This study performs a systematic review on the clinical application of 3D-printed (3DP) for conservative management of injuries.

Methods: The search phrase “(3d printed cast) AND ((fracture) OR (injury) OR (tendon))” was entered into PubMed, yielding 50 results published between 2015 and 2024. 15 articles were included in this review.

Results: 3 studies showed proof-of-concept in a non-clinical setting for 3DP casting using biomechanical and materials testing in both UE and LE models. 5 clinical studies without a control group reported overall patient satisfaction and good to excellent clinical healing of UE fractures with 3DP but also reported incidents of cast breakage. 7 studies in a clinical setting showed that 3DP casting is superior to conventional fiberglass in patient satisfaction and non-inferior in clinical efficacy.

Discussion: Based on the current literature, this study proposes a novel 3D-printed cast that provides immobilization at the maximum plantar flexion required for Achilles tendon healing and eliminates the need for constant cast changes in a non-surgical treatment plan. The proposed device will act to maintain stability and reapproximation for healing at the injury site, whilst providing easy access for hygiene and wound care, thus mitigating the risk of infections and promoting optimal healing. Future direction will establish proof-of-concept using finite element analysis for customization of stress distribution and biomechanical testing for load-bearing analysis. By extending its usage to acute Achilles tendon injuries, 3DP casting has the potential to enhance outcomes for non-surgical candidates.

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