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The aim of this research study centers around the design and development, using a three-dimensional model of an ear-splint. This study results from the need of a non-invasive method, as the current techniques used in otoplasty have succeeded in reducing the risk of complications, but without drastically reducing the rate of postoperative deformity. Indeed, stick out ears present a deformity that occurs in 5% of the population. Factors such as psychosocial impact and intimidation lay the foundations for the need for such a method. This paper essays to create, through 3D printing, a case customized into the ear of any person of all ages. The splint was made on Zortrax M200 3D printer model, equipped with the V3 Hotend head, and the material used for printing was 16 grams of Z-FLEX. It is noted that the creation of the case is innovative and original. After putting the ear-splint into test, by applying it on a human ear, two conclusions emerge. First, it is very light, weight, just 16 grams, and second, it offers comfort and convenience to the user. In order to get results for its practicality, a clinical rehabilitation study is recommended.

Three-dimensional (3D) printing is a leading manufacturing technique in the medical field. The constantly improving quality of 3D printers has revolutionized the approach to new challenges in medicine for a wide range of applications including otoplasty, medical devices, and tissue engineering. The aim of this study is to provide a comprehensive overview of an artificial ear splint model applied to the human auricle for the treatment of stick-out protruding ears. The deformity of stick-out protruding ears remains a significant challenge, where the complex and distinctive shape preservation are key factors. To address this challenge, we have developed a protocol that involves photogrammetry techniques, reverse engineering technologies, a smart prototype design, and 3D printing processes. Specifically, we fabricated a 3D printed ear splint model via fused deposition modelling (FDM) technology by testing two materials, a thermoplastic polyester elastomer material (Z-Flex) and polycaprolactone (PCL 100). Our strategy affords a custom-made and patient-specific artificial ear aligner with mechanical properties that ensures sufficient preservation of the auricular shape by applying a force on the helix and antihelix and enables the ears to pin back to the head.