Following the work done previously on design and simulation of a new finger support, this paper focuses on mechanical testing, methods of fabrication using a LaserJet 3D printer and also explores a better polymer which can be used for the support. The special composite finger support was designed for the first time to accommodate the patients with all sort of finger deformity. A new model is presented here, which is the optimum design suggested previously and is consisted of polymeric support with an inserted sheet of aluminum or carbon fiber. After presenting the results of modeling (including the calculated maximum stress and maximum deformation), the maximum stress values were compared with the yield strength values of the metals and it was noticed that the support does not undergo any plastic or permanent deformation. Furthermore, in order to validate the modeling results, the support was fabricated and mechanical tests were conducted. The steps and details of designing, simulation, mathematical confirmation using MATLAB (Mathworks©) package, fabrication, and mechanical testing are all presented. Overall the finger support is reliable and strong and can be brought to the market.

This paper reports on the results of design and fabrication of a new finger support. Finger deformation is very common and has many causes and severity. Most of the available finger supports are not resizable and comfortable. They are mainly designed to fully restrict the finger’s motion when there has been any type of injury. However, for example in the case of early stages of arthritis, the patient should be able to use them whenever they want. Furthermore, the available finger supports cannot be adjusted considering various fingers’ sizes and positions. In this research, seven models of a polymer-metal composite finger support are designed. They are made of a soft polymer with inserted sheets of aluminum, steel or carbon-fiber. The optimal models are strong, and allow for size and finger position adjustments, and can be used for patients who already have distorted fingers and are working on them to regain some functions. Extensive finite element analysis of the support under the distributed loads of the finger, confirmed by the results obtained by a MATLAB program, shows that the new support tolerates the applied forces without any permanent deformation. Finally, the fabricated part using 3D printing validates the results.

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