ALLPCB
Overview
NovaCast is a 3D-printed medical splint. It can help prevent infections, ulcers, and amputations. It is about ten times lighter than traditional materials and provides strong ventilation.
Background and Development
Traditionally, doctors have used plaster splints to support patients during bone recovery. Plaster splints are often heavy, impede medical inspections, and have poor ventilation, which can promote infections, ulcers, and in severe cases lead to amputation. To address these issues, a group of graduates from the National Autonomous University of Mexico (UNAM) founded the startup Mediprint and developed the NovaCast splint using 3D printing.
Materials and Advantages
"Conventional splints mainly use highly hygroscopic plaster as the material, which means it absorbs sweat and, because it is not ventilated, allows bacteria to proliferate," said Zaid Musa Badwan, a UNAM mechatronics graduate and founder of Mediprint.
According to the team, NovaCast is patented and replaces traditional casting molds with 3D printing. Its advantages include being roughly ten times lighter than plaster splints, imposing fewer movement restrictions on patients, offering an improved appearance, and supporting customization. Patients can also wear the splint while showering.
Clinical Motivation
"The project began after my mother fractured her left hand in a car accident. The first splint applied by doctors was incorrect, and later they had to surgically separate and realign the bones to correct the issue. A subsequent splint was fitted incorrectly again. As a result, her hand was diagnosed as 50% disabled," Badwan said.
He added that some patients suffer amputations due to improper plaster use combined with bacterial growth. If a splint is applied incorrectly and the bones heal poorly, it can permanently affect mobility.
Customization and Production
The team also developed software that defines the precise splint dimensions from specific patient measurements without requiring a 3D scan. "Doctors only need to input the measurements and the software will automatically generate an optimal geometry for 3D printing," Badwan said.
Production currently takes about three and a half hours per splint, depending on patient size. "We are refining the process with the goal of reducing that time to one hour. The next steps include deploying the technology in hospitals, expanding 3D printing capacity, and producing surgical tools, custom templates, or anatomical teaching models," Badwan said.
