Finger Orthoses for Rehabilitation―Part I: Biomedical Insights and Additive Manufacturing Innovations
Alireza Nouri, Lijing Wang, Hamed Bakhtiari, Yuncang Li, Cuié Wen
Abstract
Background: Finger orthoses are essential for treating injuries, deformities, and disorders of the upper limbs by supporting, immobilizing, or correcting deformities. Recent advances in three-dimensional (3D) printing have significantly enhanced precision and customization compared to traditional fabrication methods such as thermoplastic molding, plaster or fiberglass casting, and the use of prefabricated splints. Methods: The present review was conducted using PubMed, Scopus, and other databases with keywords such as “hand therapy”, “additive manufacturing”, “finger and thumb”, and “orthosis”. Only English-language publications were considered, with a primary focus on articles published between 2010 and 2025. Key themes were identified and categorized into conditions necessitating finger orthoses, types and classifications, ergonomic design considerations, and advancements in additive manufacturing. Results: Finger orthoses address musculoskeletal injuries, inflammatory diseases, and neuromuscular disorders. Three-dimensional printing provides enhanced customization, reduced material waste, rapid prototyping, and the ability to create complex geometries, improving patient comfort and functionality. Conclusions: Finger orthoses effectively treat various conditions by supporting and stabilizing fingers. A thorough understanding of anatomy, biomechanics, and fabrication methods is crucial for achieving functional and comfortable designs. Three-dimensional printing offers a transformative approach to producing lightweight, customizable, and cost-effective orthoses, enabling innovative and personalized solutions. By bridging clinical needs and design strategies, this review may guide future innovations in patient-specific orthotic development.