3D printing buries plaster in Catalonia: goodbye to the itch

Published on June 06, 2026 | Translated from Spanish

Catalan healthcare takes a step forward by replacing traditional plaster casts with 3D-printed splints. This new method creates customized immobilizers that are lighter and more breathable, promising to eliminate classic discomforts. For patients, this means less weight, zero itching, and a less tedious recovery, reducing follow-up visits and associated treatment costs.

Hospital room scene, doctor holding a lightweight 3D-printed lattice forearm splint while a patient shows relief, traditional plaster cast discarded on a table beside a 3D printer with a glowing build plate, patient smiling, breathable plastic mesh structure visible on the splint, soft clinical lighting, photorealistic medical visualization, clean white walls, advanced medical technology atmosphere, high detail on printer nozzle and splint texture

Digital scanning and custom design for every fracture 🖨️

The process begins with a 3D scan of the affected limb, eliminating plaster molds. Software translates that data into a splint design with a honeycomb structure, providing rigidity without weighing it down. The printer uses filaments such as PLA or nylon, biocompatible and recyclable materials. The result is a ventilated, hypoallergenic piece that can be fitted in minutes. Additionally, being removable for hygiene, it facilitates medical follow-up without needing to cut or redo the bandage.

Plaster casts retire (and the leg bone won't miss them) 😂

Goodbye to that cement cylinder that weighed like a ton and smelled like a damp basement. With the 3D splint, patients will be able to scratch their leg without resorting to a bent coat hanger. Of course, the new invention has a danger: if before you boasted of an autograph signature on the plaster, now you'll have to ask the doctor to scan a doodle for you. Modernity has its prices.