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3D-Printed Wrist Brace

The 3D-printed wrist brace is a customizable, low-cost solution designed to provide support for wrist injuries. Unlike traditional wrist braces, this one is printed flat on the 3D printer bed and later molded to fit any wrist shape using PLA’s low melting point.

By dipping the brace in boiling water, the PLA softens, allowing it to be molded around the wrist for a perfect fit. The project introduced me to PLA thermal properties, anatomical 3D modeling, and brace ergonomics.

Following this project, I began exploring similar applications, including thumb splints and ankle braces, using the same PLA molding technique.

Step-by-Step Working

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  1. 3D Modeling and Printing:
     

    • I designed the brace using Fusion 360, ensuring that the model would print flat to maximize strength and reduce material waste.

    • The model includes perforations for breathability and flexibility.

    • It was printed using PLA filament, which has a low melting point of approximately 60°C (140°F).

    • The flat print design reduces print time and filament usage, making it efficient and cost-effective.
       

  2. Molding Process:
     

    • After printing, the flat brace is immersed in boiling water for 15-20 seconds.

    • The heat softens the PLA, making it pliable.

    • While still warm, the brace is wrapped around the wrist and gently pressed to conform to the wrist’s shape.

    • Once cooled, the brace hardens, retaining its custom shape.
       

  3. Application and Fit:
     

    • The brace provides firm support and restricts wrist movement, making it ideal for mild sprains, carpal tunnel syndrome, and post-injury stabilization.

    • Its lightweight, breathable design makes it comfortable for daily use.

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