Advances in additive manufacturing technologies and composite materials are starting to be combined into synergic procedures that may impact the biomedical field by helping to achieve personalized and high-performance solutions for low-resource settings. In this article, we illustrate the benefits of 3D-printed rapid molds, upon which composite fibers can be laminated in a direct and resource-efficient way, for the personalized development of articular splints. The rapid mold concept presented in this work allows for a flexible lamination and curing process, even compatible with autoclaves. We demonstrate the procedure by completely developing an autoclave-cured carbon fiber–epoxy composite ankle immobilizing, supporting, or protecting splint. These medical devices may support patients in their recovery of articular injuries and for promoting a more personalized medical care employing high-performance materials, whose mechanical response is analyzed and compared to that of commercial devices. In fact, this personalization is fundamental for enhanced ergonomics, comfort during rehabilitation, and overall aesthetics. The proposed design and manufacturing strategies may support the low-cost and user-centered development of a wide set of biomedical devices and help to delocalize the supply chain for involving local populations in the development of medical technology.

The present work focuses on studying and demonstrating the potential benefits of non-planar printing, as compared to conventional 3D printing, in terms of improved eco-impacts. To this end, a case study of a medical or ergonomic device, which may benefit from non-planar printing in different ways, is completely developed and manufactured employing alternative approaches, which are quantified, as regards production costs and environmental impacts. Three 3D printing processes are used: two of them relying on non-planar printing, one using conventional 2D printing trajectories. Relevant benefits are achieved thanks to the possibility, enabled by non-planar 3D printing, of manufacturing products upon reusable rapid tools. These support tools constitute an interesting alternative to the support meshes generally employed in additive manufacturing, which are normally a relevant source of waste and involve costly post-processes.

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