Design, Parametric Modeling, and Additive Fabrication of a Customized 3D-Printed Orthopedic Splint for Veterinary Sports Management and Rehabilitation of Canine Ankle Injuries

Abstract

This study presents the development of a fully customized canine ankle splint using a streamlined digital-to-fabrication workflow. The process began with a precise 3D scan of the affected limb, which allowed the creation of an anatomically accurate CAD model tailored to the dog’s joint structure. The design incorporated biomechanically informed features such as ventilation openings, smooth internal contours, and strategically varied wall thickness to balance comfort and stability. The splint was produced using dual-material FDM printing, where PLA offered strong dimensional stability and PETG provided greater flexibility and resilience in areas that directly contact the skin. By optimizing printing parameters and material placement, the final splint achieved a lightweight yet robust structure that fit significantly better than conventional off-the-shelf supports. Veterinary evaluation showed improved immobilization, reduced chances of skin irritation, and increased comfort during rehabilitation. Overall, the work demonstrates that integrating 3D scanning, parametric modeling, and affordable additive manufacturing can deliver highly personalized orthopedic solutions for canine ankle injuries, making the approach practical for everyday veterinary care.

Introduction

The study explores the development of customized 3D-printed orthopedic splints for canine distal limb injuries, addressing the limitations of conventional off-the-shelf devices, which often fail to conform to complex ankle anatomy, causing instability, discomfort, and skin issues. Using 3D limb scanning, parametric CAD modeling, and multi-material Fused Deposition Modeling (FDM), the research produced a splint combining PLA for rigidity and PETG for flexible, skin-contact regions, optimizing anatomical conformity, comfort, and immobilization performance.

The workflow included digital data acquisition, parametric design with stress-guided reinforcement, and multi-material 3D printing, followed by clinical evaluation and qualitative mechanical testing. The resulting splint demonstrated high dimensional accuracy (deviations <1 mm), balanced mechanical properties, reduced weight, improved ventilation, and superior fit compared to commercial alternatives. Veterinary assessment confirmed enhanced comfort, uniform pressure distribution, and ease of application without skin irritation.

The study highlights the advantages of additive manufacturing in veterinary orthopedics, including the ability to produce patient-specific, cost-effective, and clinically adaptable devices. It emphasizes the potential of multi-material FDM splints to improve immobilization, reduce pressure-related complications, and enhance rehabilitation outcomes. Limitations include the need for quantitative mechanical testing and long-term clinical trials, but the results support wider adoption of digital fabrication workflows in small-animal orthopedic care.

Conclusion

This study demonstrates that customized, 3D-printed canine ankle splints, developed through an integrated workflow of 3D limb scanning, parametric CAD modeling, and multi-material FDM fabrication, provide a clinically effective alternative to conventional off-the-shelf splints. The combination of PLA and PETG enabled a balanced mechanical performance, delivering both structural rigidity for immobilization and localized flexibility for comfort. The resulting splint exhibited excellent anatomical conformity, reduced weight, enhanced ventilation, and improved ease of application. The workflow proved to be cost-effective, efficient, and readily adoptable in routine veterinary practice, offering a scalable approach for patient-specific orthotic solutions. While initial evaluations indicate superior fit, comfort, and functional performance compared with standard splints, further studies involving long-term clinical trials and quantitative mechanical testing are warranted. Overall, customized 3D-printed ankle splints represent a promising avenue for enhancing rehabilitation outcomes and animal welfare in veterinary orthopedics.

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Copyright

Copyright © 2025 S. Ranjithkumar , B. R. Harivansh , K. K. Harinni . This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.