(M1430-09-50) Creating Personalized 3D-Printed Finger Splints with Ibuprofen-Loaded Nanofibers for Quicker Healing Using CT Scans

Purpose: Advanced imaging, 3D printing, and pharmaceutical technologies can be combined to create innovative custom medical devices. This study explores the creation of personalized finger splints using CT imaging, Stereolithography (SLA) fabrication, and Polycaprolactone (PCL) nanofibers loaded with Ibuprofen. These customized 3D-printed finger splints are designed to precisely fit the patient's unique anatomy, improving comfort, support, and healing efficiency in medical cases. In addition, the PCL nanofibers loaded with Ibuprofen offer targeted, sustained drug release and enhanced pain relief for broken fingers, promoting faster and more efficient healing with reduced systemic side effects.

Methods: A 3D model of a broken finger was created from high-resolution CT scans using specialized software, and then printed as a custom-fit splint using SLA technology (see Fig. 1). The splint was coated with Ibuprofen-loaded PCL nanofibers using electrospinning. The accuracy and strength of the printed splint were tested by comparing measurements with the original 3D model and conducting mechanical tests. The coated splint also underwent various assessments to evaluate the properties of the PCL nanofibers, including Water Contact Angle, Differential Scanning Calorimetry (DSC), Fourier Transform Infrared Spectroscopy (FTIR), Thermogravimetric Analysis (TGA), X-ray diffraction (XRD), Scanning Electron Microscopy (SEM), cytocompatibility, and skin penetration

Results: The high-resolution CT scans of the broken finger were processed using specialized software to separate the bone from the soft tissue. This segmentation was then used to create a 3D model, which was saved as an STL file. The STL file was printed using SLA technology to make a custom-fit splint. The 3D-printed splint closely matched the original STL file, ensuring a precise fit for the patient. Furthermore, the DSC analysis showed that Ibuprofen inside PCL fibers had completely changed to its amorphous form, as depicted in Fig. 2. Additionally, Fig. 3 confirmed the chemical composition and functional groups in the PCL nanofiber loaded with Ibuprofen through FTIR analysis, ensuring successful drug incorporation into the nanofiber matrix.

Conclusion: The combination of CT imaging, SLA 3D printing, and PCL nanofibers loaded with Ibuprofen offers a promising approach for creating custom therapeutic finger splints. The results show the potential for precise, patient-specific splints that not only immobilize but also provide localized drug delivery to improve healing outcomes. Additional tests, including nanofiber characterization, cytocompatibility, and skin penetration studies, are underway to further confirm the effectiveness and safety of the coated splints.


Figure 2. DSC curves of Ibuprofen, Polycaprolactone, Their physical mixture and the prepared nanofibers.

Figure 2. FTIR Spectra of Ibuprofen (a), Polycaprolactone (b), Their physical mixture (c) and the prepared nanofibers (d).