Personalized Cast
After going for a ride on a skateboard I found myself flying through the air after an errant pebble found it’s way in my path. Trying to catch myself I jammed the middle finger on my left hand. Immediately it was painful to bend. Using a 3D scanner to create a digital replica of my hand and used a combination of Fusion360 and nTop to model up a latticed splint. The Voronoi lattice was chosen to allow air flow for comfortability, while still offering a rigid body for protection. The splint was printed on a Bambu FDM printer out of ABS with zero support structure.
Original 3D Scan
The original 3D scan was done in two parts, the palm side first, and then the back of the hand. Positioning triangles were used to help stitch the two scans together, with accuracy focused onto the injured finger.
Isolated Finger
From the raw scan, the injured finger was isolated. A shell was then formed as the basis of the splint with a 1.5mm wall thickness. A small slit was then added to allow slight deformation when putting the splint on.
Latticed Pattern
After finalizing the overall shape, I created a Voronoi Surface Lattice with 100 points across the finger, and a beam thickness of 2.5 mm. A Boolean operation between the lattice and shell created the final splint.
Final Splint
The final version of the splint was printed vertically on an Bambu H1D without any support structures out of ABS.
