My wife broke her toe. Since I had recently purchased a 3D printer, I went about seeing if I could help the situation by printing her a splint. I found the splint made by laird when he was in a situation similar to mine (https://www.thingiverse.com/thing:38286). I liked the design, but wanted to try to make one a little more streamlined.
The process took me through four iterations:
-Version 1 is crude and didn't support the toe very well. This one is not recommended, but I added it for a view at the design process.
-Version 2 is longer on one side for more support. Toe webbing allows for longer support on one side rather than the other. V1 didn't account for this.
-Version 3 adds a slit in the end to allow some flexibility as the broken toe swells.
-Version 4 adds some holes at the end to enable a little air flow (less toe stink). My wife highly recommends V4. She calls it her "toe hat."
Use is fairly simple. This splint is customized to a toe on the right foot. For the left side, print a mirror. Scale larger or smaller as needed for fit. Once printed, place gently on toe and tape in place.
The walls on V2-V4 are only 1mm thick. This is thin enough to not cause discomfort on the foot, while still providing support to allow the toe to heal straight.
I hope this helps. Happy healing!
I printed in both PLA and PETG. Both worked successfully. The PETG seemed more flexible and stronger. Printing in clear PETG adds a little "bling" to the splint.
Supports may not be needed. I used supports touching the print bed only to help get the print started well. Supports don't seem to be needed for the overhangs at the top.