Immediate Outcomes and Benefits of 3D Printed Braces for the Treatment of Adolescent Idiopathic Scoliosis.

Spinal bracing is a proven effective treatment for children with adolescent idiopathic scoliosis (AIS). Four factors have been reported to affect brace treatment outcome including (1) growth or curve-based risk, (2) the in-brace correction, (3) the brace wear quantity, and (4) the brace wear quality. The in-brace correction is impacted by spinal flexibility. The quality of brace design also affects the in-brace correction and comfort which indirectly affects the brace wear quantity and quality. A traditional polypropylene spinal brace is bulky and uncomfortable, and its manufacturing process is labor intensive. As 3D printing technology becomes more common and advanced, there is a potential to manufacture spinal braces using 3D printing technology. The objectives of this paper were to report the immediate effectiveness and benefits in using 3D printed brace to treat children with AIS. Six children with AIS (5F, 1M; 12.9 ± 1.4 years old; Cobb angle: 26° ± 7°), who were new to brace treatment, were recruited. Spinal flexibility and pressure pad locations were acquired using ultrasound assisted method to ensure braces were designed properly. To manufacture the braces, all participants were scanned by a handheld 3D scanner to obtain their body shapes. The 3D braces were then printed with Nylon 12 material. The average in-brace Cobb angle correction was 10 ± 4° (41 ± 18% correction). The 3D brace was 33% thinner, 26% lighter, 37% lower cost and required 3.7 h less labor time to manufacture when compared with the standard polypropylene brace. As a conclusion, the 3D printed brace had good immediate treatment effectiveness, but the long-time effect is still required time to explore.