All posts
Technology

How a Struxa splint is made: additive manufacturing, explained

A Struxa splint doesn't come off an injection-mold line. It's additively manufactured — built up layer by layer from an engineered digital design.

A Struxa splint building up layer by layer during printing

Additive manufacturing lets us make shapes that traditional manufacturing simply can't — like a continuous open lattice with no seams and nothing to assemble. It's the reason a Struxa splint can be so light and so breathable at the same time.

From design to structure

Every splint starts as an engineered digital model. The open-lattice geometry — where each strut sits, how thick it is, how it curves around the finger — is worked out in software long before anything is printed. That design stage is where the support and the comfort are dialed in.

Printed layer by layer

The printer then builds the splint one thin layer at a time, fusing material into a single continuous piece. There are no glued joints or fasteners to loosen: the lattice, the frame, and the strap anchors are all one structure. That's a big part of why it holds up to everyday wear.

Why additive manufacturing suits a splint

  • Complex open lattices that would be impractical to mold
  • A one-piece structure with no seams or assembly
  • Consistent, repeatable geometry from one splint to the next
  • The freedom to refine the design as we learn

Made in Colorado

We design and print in-house in Colorado, which keeps quality close to home and the feedback loop short. Every Struxa splint is engineered and manufactured here — from the first line of the digital model to the finished piece in your hand.

Light, breathable, and built as one — the way an open lattice was meant to be made.

See what the process makes possible

Two collections, built on one open-lattice architecture.

Explore products