Orthotics, 3D printing and prosthetics: Focus on hand care

Digital technologies are expanding the possibilities in upper extremity care. Three current examples demonstrate how medical technology, 3D printing, and therapy are converging to create more precisely fitted assistive devices and tailor rehabilitation processes more effectively.

Personalization is at the heart of this: solutions are increasingly tailored to individual anatomical conditions, functional requirements, and the course of therapy. This can be particularly crucial in hand and wrist care, as even small functional improvements can significantly ease daily life.

One approach involves smart hand orthoses that not only assist with movement but also detect it through sensors and provide haptic feedback to the user. A research team at Friedrich-Alexander University Erlangen-Nuremberg (FAU) is developing a bidirectional interface that uses muscle impulses for control while simultaneously capturing information – such as grip strength – via sensors and conveying it through tactile signals.

Overview of potential benefits:

• More precise control of grasping movements
• Improved assessment of force and movement
• Greater independence in daily life

As a result, the use of orthoses can become more intuitive, since movements are not only performed but also perceived. This can play a central role in functional rehabilitation.

In addition to sensor-based solutions, the focus is also shifting more toward the production of customized assistive devices.

Another approach is emerging through the use of additive manufacturing in orthopedic technology. Among others, Stralsund University of Applied Sciences is working on this in collaboration with clinical and technical partners. Based on digitally captured anatomical data, patient-specific hand orthoses are developed, designed, and manufactured using 3D printing. The process encompasses the entire digital chain, from data capture through simulation and design to manufacturing.

Overview of potential benefits:

• High fit accuracy through individual customization
• Ergonomically optimized structures for greater freedom of movement
• Flexible adjustment during the course of therapy

The goal is to provide a solution that not only adapts to the anatomy but also proves effective in everyday life. The combination of digital development and additive manufacturing can help better address functional requirements and make treatment processes more efficient.

While orthoses primarily serve a supportive function, personalized approaches are also emerging in surgical care.

The trend toward more personalized solutions is also evident in surgical care. One example comes from the BG Universitätsklinikum Bergmannsheil in Bochum, which uses specialized wrist prostheses. When conservative treatments have been exhausted, replacing the joint with a prosthesis can help reduce pain while preserving mobility. Implants made of biocompatible materials take over the function of the damaged joint and enable movement that is nearly natural.

Possible benefits at a glance:

• Preservation of functional mobility in the wrist
• Reduction of chronic pain
• Improved resilience and ability to perform daily activities

In combination with targeted post-operative physical therapy, this treatment can help gradually restore strength, coordination, and range of motion, thereby supporting a return to daily life and work.

These examples illustrate how care processes could increasingly be organized as an end-to-end, digitally supported chain, starting with the collection of individual data, through manufacturing, and on to therapeutic application.

The added value of this development:

• more precise fitting of assistive devices
• more efficient care processes
• greater focus on individual needs

This results in care that combines technical possibilities with functional requirements and real-life application, thereby opening new perspectives for hand rehabilitation.

Sources: BG Bergmannsheil University Hospital, Bochum (German only), Friedrich-Alexander-Universität Erlangen-Nürnberg, Stralsund University of Applied Sciences