Overview
NovaCast is a 3D-printed medical splint designed to reduce infection, ulcers, and the risk of amputation. It is about ten times lighter than traditional materials and offers high ventilation.
Limitations of Traditional Plaster Splints
Traditionally, physicians use plaster splints to support bone recovery. Plaster splints are heavy, hinder medical examinations, and are poorly ventilated, which increases the risk of bacterial growth, infection, and ulcers. To address these issues, a group of graduates from the National Autonomous University of Mexico (UNAM) founded the startup Mediprint and developed NovaCast using 3D printing.
Design and Advantages
"Conventional splints use highly hygroscopic plaster as the material, which means it absorbs sweat and, because it is not ventilated, it easily allows bacterial growth," said Zaid Musa Badwan, a UNAM mechatronics engineering graduate and founder of Mediprint.
According to reports, the students have patented NovaCast. The product replaces traditional casting molds with 3D printing. Its advantages include being about ten times lighter than traditional plaster splints, imposing fewer movement restrictions, offering an improved appearance and customization options, and being water-tolerant enough for patients to bathe while wearing it.
Motivation and Clinical Concerns
"The project began after my mother fractured her left hand in a car accident. Doctors applied an incorrect splint, and later had to surgically re-break the bones to correct them. They once again applied the wrong splint. As a result, they now assess her hand as 50% disabled," Badwan said.
He added that some patients have required amputation due to improper use of plaster and bacterial growth. If a splint is applied incorrectly and the bones heal poorly, it can permanently affect mobility.
Software and Manufacturing Process
The team also developed software that calculates a splint's dimensions precisely from specific patient measurements, eliminating the need for a 3D scan. "Doctors simply enter the measurements and the software automatically generates the ideal geometry for 3D printing," Badwan said.
Depending on patient size, producing one NovaCast currently takes about 3.5 hours on average. The team is working to reduce that time to around one hour. Their next steps include deploying the technology in hospitals, adding 3D printers, and expanding 3D printing capacity to produce surgical tools, custom templates, and anatomical teaching models.
