Thermoplastic splinting materials are among the most versatile and customizable tools for assistive technology projects. While designed for medical splints and other orthotics, these heat-activated plastics can be shaped into almost any form. This moldability makes them perfect for customizing tools, creating adaptive devices, or repairing existing equipment. The materials vary in qualities like drape, malleability, and bonding ability, allowing you to select the right type to create highly personalized and durable assistive technology solutions. Let’s explore the endless possibilities and learn how to make the most of these versatile materials.
This content does not offer medical or occupational therapy advice, diagnosis, or treatment and is for educational purposes only. We hold no liability for damages resulting from website use or information. Users are advised to consult qualified healthcare professionals for their health and functional concerns. Read full disclosure here.
Thermoplastic splinting materials for assistive technology. Pictured: button hook, cuff handle, hair brush with adapted handle, small adapted bottle cap, pen with custom grip, adapted key, and adapted fork.Who Can Use Thermoplastic Splinting Materials for Assistive Technology?
Thermoplastic splinting materials are primarily used by healthcare professionals like occupational therapy practitioners (OTPs), physical therapists (PTs), orthotists, and certified hand therapists (CHTs), who are trained in customizing splints for patients. These materials are essential for treating conditions such as injuries, arthritis, neurological impairments, or post-surgical recovery. While these professionals are the primary users, others like rehabilitation professionals can also work with thermoplastic splinting material if properly trained.
Why Use Thermoplastics for Custom Assistive Technology?
Thermoplastics combine durability, flexibility, and ease of use, making them ideal materials for assistive technology projects. Key benefits include:
- Prevent Material Waste: Physical and occupational therapists, orthotists, and other medical professionals who create thermoplastic splints can use their leftover scraps to create small assistive tools instead of throwing them away.
- Customizable Shape and Size: Splinting material can be molded into any shape, conforming around existing items or creating new assistive tools in any desired shape and size.
- Reusable: Made a mistake or need to modify the creation? Heat the material again to modify or repurpose your creations.
- Strong and Lightweight: Create durable, long-lasting assistive technology solutions.
- Skin-Safe Options: Medical-grade thermoplastics are designed to be non-irritating and safe for prolonged contact with skin.
Main Types of Thermoplastics
- Low-Temperature Thermoplastics: Softens at 135–180°F. This is the most recommended type for assistive technology solutions due to its safer working qualities, ease of molding, adaptability to various shapes, and ability to provide a custom fit.
High-Temperature Thermoplastics: They soften at temperatures from 266-320°F. While durable, these materials require high temperatures that can be difficult to manage safely, posing risks of burns and potentially damaging sensitive items. Specialized equipment is needed for molding, making them less user-friendly and accessible for everyday assistive technology solutions, where flexibility and safety are key.
New to Splinting Materials or Not Sure Where to Start?
If you’re new to splinting materials or unsure where to start, student or sample kits are a great place to start. These kits, such as the Rolyan Student Splinting Pack or the North Coast Medical Moderate to Maximum RTS Sample Kit, offer a cost-effective way to experiment with a variety of splinting materials in smaller quantities. This approach allows you to familiarize yourself with different options and techniques before committing to larger, more expensive purchases. Whether you’re learning the basics or refining your skills, these kits provide the perfect opportunity to practice and build confidence in your abilities.
Thermoplastic splinting material sheets. Student pack from Rolyan.Choosing the Right Splinting Material for Assistive Technology Projects
Understanding the key properties of thermoplastic splinting materials will help you select the right type for your assistive technology project. Each property determines how the material will perform and can guide you in designing effective and durable solutions:
Thickness
- Definition: Thickness correlates to how strong the material is. Typical thickness ranges from 1/16″ (lightweight) to 3/16″ (maximum rigidity)
- Thicker materials: Ideal for larger devices requiring durability and strength, such as device stands, handles for utensils, or heavy-duty functional orthotics.
- Thinner materials: Suitable for smaller, precise adaptations like finger grips on writing tools, key holders, or small container adaptations.
Bonding
- Definition: Bonding refers to how well the thermoplastic sticks to itself when heated.
- Uncoated materials: Best for projects involving layering, integrating other materials (like plastic tools or devices), or folding thermoplastic onto itself for extra strength.
- Coated materials: Easier to work with for simple shapes like basic hand cuffs or splints where adhesion is not required.
Drape (Conformability)
- Definition: Drape, also referred to as conformability) describes how easily the material conforms to surfaces when heated.
- Higher drape: Use for projects needing detailed shaping, such as custom hand molds for gripping tools, utensils, or toothbrushes. It’s also ideal for creating supports for irregularly shaped devices.
- Lower drape: Better for flatter or less intricate designs like handles, functional splints, or basic mounting platforms.
Resistance to Stretch
- Definition: High resistance to stretch means the material requires extra force to stretch and tends to retain its shape. Low resistance to stretch means the material stretches easily, changing shape as it is pulled.
- Minimal resistance to stretch: Suitable for small, finger-based solutions like custom grips for pens or precise adaptations with texture and detail.
- Maximum resistance: Ideal for heavy-duty or high-stress devices, such as wheelchair armrests, sturdy gripping aids for tools, or large platforms that need to maintain structural integrity over time.
Safety Precautions for Working with Thermoplastics
When working with thermoplastics for assistive technology projects, it’s important to follow safety precautions to prevent injuries and ensure successful results:
- Follow manufacturer guidelines: Always adhere to safety instructions provided by the material manufacturer.
- Use appropriate tools: For low-temperature thermoplastics, use a heat gun or water bath. For high-temperature thermoplastics, use specialized equipment like industrial ovens or heated molds. Tongs or spatulas are needed for removing heated materials from a water bath.
- Wear protective gloves: Wear heat-resistant gloves as needed to avoid burns.
- Avoid overheating materials: Do not overheat thermoplastic splinting materials, as they can degrade, release harmful fumes, or burn the skin.
- Ensure safe cooling: Allow the material to cool to a safe working temperature before applying it to skin to avoid burns or skin irritation.
- Work in a well-ventilated area: Ensure good airflow to prevent inhaling fumes from heating thermoplastics.
- Keep flammable materials away: Keep any flammable objects away from heat sources during the process.
How to Use Thermoplastics in Assistive Technology Projects
General Steps
- Heat the Material: Use hot water, a heat gun, or a splint pan to soften the plastic. Always follow the manufacturer’s recommended temperature guidelines.
- Shape the Plastic: Mold the heated plastic around the object and/or hand into the desired shape using your hands or tools.
- Cool to Set: Hold the shape until the plastic hardens, typically within a few minutes. Submerge in cold water to speed up the process.
- Refine as Needed: Use a heat gun or re-dip to trim or fold over excess material or reheat to adjust the design.
Assistive Technology Ideas for Thermoplastics
Custom Grips and Handles
Create ergonomic grips for items like eating utensils, writing aids, or grooming tools by molding thermoplastic to enhance grip strength and comfort. Adding textured or contoured surfaces for hand contact can further improve usability. For example, you can wrap and shape the material around a hair brush handle to assist individuals with joint instability and weakness.
A custom molded brush handle was made using Rolyan 1/6″ Polyform splinting material, which enabled a highly customized and hand conforming hair brush handle. This design offers joint protection and hand stabilization for a static grasp.A cuff style holder made from 1/8″ Rolyan Polyform is secured to the back of a cell phone case to assist with cell phone handling due to hand weakness.
Universal Cuff Alternatives
Custom-fabricated universal cuff alternatives using thermoplastic splinting materials offers a durable and highly individualized solutions for tasks like oral care, eating, and handling electronic devices. Unlike traditional universal cuffs, splinting materials are molded to conform to the unique contours of the hand, providing a snug and secure fit that enhances control and comfort. Thermoplastic construction provides enhanced strength and durability compared to pre-fabricated options, making it ideal for individuals seeking a reliable and long-lasting assistive device to support daily activities.
A universal cuff alterative made from Rolyan Polyflex II with perforations holds a toothbrush. This pocket style design could also hold a utensil, makeup brush, or other tools.
A cuff style holder made from splinting material is secured to the back of a cell phone case to assist with cell phone handling due to hand weakness.Writing Aids
Custom writing aids made from thermoplastic splinting materials provide highly personalized solutions for individuals with hand or finger weakness. They are molded to conform to the unique shape of the user’s hand, ensuring a secure and comfortable grip on a pen or pencil. By stabilizing the writing instrument and redistributing effort away from weaker fingers, they allow for improved control and reduced strain during writing tasks. Tailoring the design ensures that it fits not only the hand but also the specific needs of the user, making it an effective and task-specific device to promote independence with writing or drawing.
Adaptive writing aid made from Rolyan 1/8″ Polyform assists with pen grasp for a weak hand. The design also includes a zip tie and self-adhering bandage wrap for secure pen hold.
Rolyan Polyform splinting material in 1/16″ thickness was used to support a static tripod grasp around a pen.Adaptive Typing and Technology Tools
Thermoplastic materials can be used to enhance technology access by creating custom tools like touch screen stylus grips for easier navigation, keyboard typing aids for improved efficiency, or ergonomic cell phone handles for better control. These solutions provide personalized support for individuals with limited dexterity or mobility, making everyday tasks more manageable and comfortable.
This hand conforming typing aid assists with keyboard access for people who lack finger function. It could also double as a page turning device for printed materials. The extension is wrapped with self-fusing silicone tape to improve control. This tool was made out of Rolyan 1/8″ Polyform.DIY Adaptive Eating Utensils
Adaptive eating utensils play an important role in enabling independence during mealtimes for people with hand limitations. Thermoplastic can be molded into universal cuffs to securely hold utensils, shaped into weighted handles to provide control over tremors, or crafted into specialized handles such as the vertical handle pictured below.
A vertical handled fork made from Rolyan 1/8″ Synergy and a bent fork. This design works well for people who can pronate and supinate their hand but may lack other wrist and finger movements.
Custom universal cuff for a spoon made out of thermoplastic splinting material. The spoon is attached to the palmar side using rubber bands. Permanent markers were used to personalize the design.Key Adaptations
Transform a standard key into a more accessible tool by adding customized handling features with splinting materials. Enhancements like increasing the surface area for turning, adding projections for leverage, or creating a finger pocket-style design can significantly improve functionality. These modifications make small, fumble-prone keys easier to grip and manage, especially for individuals with limited dexterity or grip strength.
Adapted key holder made from Rolyan 1/8″ Synergy features a thumb pocket to improve grasp and leverage for key turning.Container Modifications
Small scrap pieces of splinting materials can be repurposed to adapt pump dispensers, lids, and other container parts, making them easier to use for people with reduced hand strength or dexterity. Container modifications like lid projections or extended surfaces improve leverage and grip, simplify tasks like pumping soap, twisting jar lids, or opening bottles. These durable, low-cost modifications provide a practical way to enhance accessibility for everyday tasks.
Splinting material scraps can be used to adapt lids and other container parts, using leverage enhancing designs and increased surface area for people with fine motor coordination deficits. Splinting material used includes Rolyan 1/8″ Ezeform on the left and Rolyan 1/16″ Polyform on the right.Create Tactile Markers for Push Buttons and Appliance Controls
Thermoplastic splinting materials are great for creating push button adaptations to small electronics and appliance controls, offering a practical solution for people with visual impairments or limited dexterity. These materials can be molded into small, raised shapes to provide tactile cues and leverage enhancements, making buttons, switches, and dials easier to identify and operate. Whether used on kitchen appliances, electronic devices, or wheelchair controls, these markers enhance independence by improving navigation and reducing the chances of accidental operation.
Using small scraps of thermoplastic materials, you can create push button adaptations and tactile enhancements for small buttons and levers.Custom Adaptive Devices Using Splinting Material
Create personalized tools tailored to specific tasks, such as securing buttons or pressing buttons and handling containers, to better meet individual needs. By going beyond standard off-the-shelf solutions, you can design entirely new assistive devices that offer customized functionality.
Button Hook
A button hook made out of thermoplastic materials is a simple and customizable assistive device for dressing. To create something similar, heat the material until soft, then mold it around a sturdy handle like a dowel for a comfortable grip. Include a sturdy metal loop at one end large enough to hook onto buttons. Let it cool and harden for a durable, ergonomic tool to assist with button up shirts and pants.
Button hook tool made from Rolyan 1/16″ Ezeform, a wood dowel, and a paperclip.Pointing Aid
Our DIY pointing aid is a wearable device designed to support pointing and pressing tasks for people with index finger weakness or joint hypermobility. Made from durable thermoplastic splinting material, it wraps snugly around the finger to provide joint protection and stability, preventing hyperextension and enhancing strength. This innovative design distributes forces evenly, reduces strain, and improves leverage, making it an effective low-tech solution for tasks like pressing buttons and opening containers, helping users achieve greater independence.
Single index finger extension may be challenging for people with finger weakness, hypermobility, or joint pain. This finger mimicking orthotic made out of Rolyan 1/8″ Polyform covers the index finger and features a faux red fingernail to assist with pushing buttons and other pointing related activities. In the picture, the orthotic is worn over the left index finger and is being used to press a microwave button.Conclusion: Thermoplastic Splinting Material for Assistive Technology
Thermoplastics combine flexibility, strength, and adaptability, making them ideal for DIY assistive technology projects. Whether modifying tools, repairing mobility aids, or designing entirely new solutions, these materials empower individuals and caregivers to enhance accessibility. Incorporate thermoplastics into your next project and experience how these versatile materials can promote greater ease and independence in everyday tasks.
