SLA 3D Printed Exoskeletal Cast to Heal Broken Bones

SLA 3D Printed Exoskeletal Cast to Heal Broken Bones

Process 3D Print, Polish
Material Resin
Quantity 1 pcs
Price Range $100-1,000
Lead Time 3 workdays


About Project

All of us know that Breaking a bone is an unpleasant thing — and having to wear a smelly, clunky plaster cast of bones is like getting kicked when you’re down. At least, that’s how the male patient felt after breaking his leg.

The doctor created the resin cast, a breathable, lightweight, recyclable, and washable exoskeleton, and ordered it from us. The 3D printed cast of bones mimics the body’s trabecular – the small honeycomb-like structure that makes up your inner bone structure.

The 3D printed cast also lets in plenty of air and due to its customized fitting and tight structure, it can fit under clothing more easily compared to traditional casts.


The steps involved are obtaining the surface data by either CT scan or 3D optical scanner, processing of DICOM or point cloud data respectively, building 3D digital model in STL format, 3D printing, finishing, and assembly.

  • Step 1: Let the patient’s family holds his broken leg with care, and the doctor scans his foot and lower leg with a high-precision handheld 3D scanner until the complete data is properly acquired. Then the scan data is imported into the CAD software, which is accurate for further processing.
  • Step 2: The doctor and our engineer cooperate to build the 3D model of the cast from the concept sketch. Its honeycomb-like structure allow the wearers to feel the surroundings and scratch the inevitable itches more freely, and most importantly, let the leg “breathe” in summer.
  • Step 3: Transfer the STL file to the SLA 3D printer. Print the two pieces of the cast with SLA ABS-like Resin, which has accurate and durable features.
  • Step 4: Carefully sand and polish the prints after the removal of the supports and excess materials and post-curing. Any blur should be avoided. Then let the patient tries it on, fixed with bands.