I created 3D CURE around the interest of closing the healthcare gap in Ethiopia. I used to visit and play with children who have disabilities in CURE hospital, and I noticed the need for appropriate orthoses. Many patients had traditional plaster casts that were uncomfortable, hard to keep dry, and caused odor, scratches, skin irritation, maceration, and infections. Some patients could not even afford proper casts or orthoses, while others relied on traditional bone setting because modern treatment was expensive or hard to access.
In Ethiopia, extremity fractures are common, and traditional bone setting is still widely used, even though it is linked to complications such as malunion, Ischemic Contracture, and severe infections. In many cases, a simple fracture treated traditionally can become a permanent disability, turning a recoverable injury into a lifelong socio-economic burden for the patient and family.
I created 3D CURE because affordable orthopedic care should not depend on geography, income, or imported medical supply chains. I wanted to use 3D printing to produce low-cost, customized, breathable braces, casts, and assistive devices for underserved patients.
In practice, 3D CURE is an end-to-end workflow that converts a doctor’s prescription into a functional medical device within days. At the hospital, we capture the patient’s limb geometry using low-cost LiDAR or photogrammetry based on the physician’s prescription. The doctor plays a crucial role in defining how the cast or brace should be designed and calibrating the patient’s limb position.
The scan is converted into a digital mesh and refined using CAD software such as Meshmixer, Fusion 360, and SolidWorks. Based on the processed scan, we design the brace for the patient’s diagnosis. The common design process includes selecting the region of the limb, extracting it, smoothing the surface, and adding thickness. We then adjust geometry, ventilation patterns such as Voronoi holes, and joint constraints based on diagnosis and age.
The device is sliced and printed using PLA or ABS filaments. Printing usually takes 6–12 hours, followed by fitting and direct feedback from clinicians and patients. The final device is lightweight, breathable, customized, and more comfortable than traditional plaster casts.
3D CURE has been spreading through hospitals, patients, medical companies, NGOs, and direct partnerships in Addis Ababa. To date, we have delivered 150+ devices, including prosthetic hands, finger splints, pediatric braces, and casts, many provided free or highly subsidized. We currently partner with 5+ hospitals in Addis Ababa and collaborate with medical companies and NGOs.
Our project has spread mainly through real patient cases. For example, we helped a baby with Erb’s palsy by designing a brace plate that allowed his hand to unfold and maintain its shape. We also helped a patient with an ulnar styloid fracture by scanning his arm, designing a custom orthosis, and delivering the brace after two days at around $5 to print.
3D CURE is also spreading through international networks and innovation platforms. We are the only Ethiopian group affiliated with E-nable Hand, and we are working under NVIDIA’s Inception program and Microsoft’s Startup Incubator. Our website, video, hospital work, and patient stories help more people understand our mission of making orthopedic care affordable and accessible.
We have modified 3D CURE through direct patient feedback, doctor supervision, and repeated hospital trials. In one early case, we helped a baby with Erb’s palsy by designing a brace plate to help his hand unfold. After delivery, we noticed that the baby’s hand was slipping out to the left, which showed us what needed to improve in future designs.
From there, we began using 3D scans more carefully to get a better fit. We added integrated Velcro-strap channels, improved the brace geometry, and used Voronoi-patterned holes to increase breathability and avoid moisture buildup. These changes help reduce discomfort, skin irritation, maceration, and infections.
We also expanded from simple braces into prosthetic hands, finger splints, pediatric braces, casts, and other assistive medical devices. Our team is further automating the process with AI to reduce manufacturing time and prepare the next generation of our workflow to design casts instantly. We are also exploring recycled PET plastic from water bottle waste to reduce filament cost and environmental impact
If you want to try 3D CURE, the first step is to contact our team through our website, explore how we would collaborate, and see whether you are interested in branching out. We are currently developing the training curriculum for students to join our initiative and learn how to design and produce medical devices and prosthetics.
For the work flow, we would scan the patient’s limb using low-cost LiDAR or photogrammetry, or collect the needed measurements if scanning is not available. The doctor would help define the limb position and the medical requirements of the brace, cast, prosthetic hand, or assistive device.
After that, we convert the scan into a digital mesh, design the device in CAD software, add ventilation patterns and joint constraints, and print the device using PLA or ABS filament. Once printed, we fit the device to the patient and collect direct feedback from the patient and clinician. If there is discomfort or fitting issue, we modify the design and improve the next version.
