Nasal Fracture
Nasal bones are the most frequently fractured in sport: they represent up to 84.7% of facial fractures in contact sports. Return to play is possible once acute swelling has resolved and airway patency is confirmed, typically 10–21 days post-fracture.
Designed exclusively to protect the nasal bones after a stable fracture. Redistributes lateral and frontal impact loads. Covers only the nasal pyramid without interfering with peripheral vision or oral communication. Indicated for isolated nasal fractures without significant displacement.
Compact piece (~45×35×30 mm) that fits comfortably on the Saturn 4 Ultra 16K platform (218×122×220 mm), allowing several units to be printed simultaneously. Vertical orientation minimizes layer lines in the impact zone. 3.5 mm thickness on the nasal dorsum. Ventilation through Ø2 mm side perforations. Interior padding with 3M waterproof Micropore on the contact surface. CAD model derived directly from the STL mesh of the facial scan.
Variant that extends protection toward the inferior orbital floor and the infraorbital rim. Indicated when nasal fracture is accompanied by periorbital edema or when there is a risk of extension to the nasoorbitoethmoidal (NOE) complex. Greater coverage without compromising vision.
The piece (~110 mm wide) fits on the Saturn 4 Ultra 16K platform (218×122×220 mm) as a single unit, diagonally oriented. The extension toward the infraorbital rim requires geometric precision: error <0.3 mm to avoid pressure on post-surgical tissue. Print supports preferably on the posterior zone (mask interior).
Minimalist variant inspired by the model worn by Fermín López after his nasal fracture. The shell covers only the nasal dorsum and leaves the nose tip open via an inverted arch. An arched forehead band above the eyebrows and four flat resin arms (two upper toward the temples, two lower toward the ears) distribute impact and keep the mask stable without covering cheeks, eyes or mouth. Indicated when the athlete needs maximum facial visibility, breathing freedom and thermoregulation.
The skeletal design reduces material and weight (~50% less than an equivalent closed mask) without sacrificing structural protection over the nasal dorsum. The full piece (~135 mm wingspan between arm tips) fits comfortably on the Saturn 4 Ultra 16K platform (218×122×220 mm) as a single unit, oriented with the forehead band diagonally. Four rectangular slots (18×4 mm) integrated at the tips allow clean passage of elastic straps without additional hardware. The forehead band and arms have a 5 mm wall for maximum stiffness with minimum material.
Orbital Fracture
The orbital floor and medial wall are particularly vulnerable to impact from objects larger than the orbit (balls, elbows, knees). Blow-out fractures may involve the inferior rectus muscle. Orbital protection is the second most frequent indication for sport masks.
Protects the supraorbital ridge, the orbital floor and the infraorbital rim. The optical-window design keeps the pupil visual field clear while protecting the periorbital bones. Indicated for stable post-reduction blow-out fractures, or as preventive protection for athletes with a previously fractured orbit.
Due to the bilateral width of the orbital rim (~140 mm), the piece is printed in two symmetrical halves (left and right) that fit comfortably on the Saturn 4 Ultra 16K 218×122 mm platform, with a central press-fit joint over the nasal dorsum. The orbital window requires rounded edges (minimum radius 3 mm) to avoid stress concentration. The infraorbital rim zone has a 4 mm wall. The model derives directly from DICOM CT segmentation, ensuring the mask does not press on bone reduction zones or implants.
Zygomatic Fracture (ZMC)
La fractura del complejo cigomatomaxilar (ZMC) involucra el arco cigomático, el piso orbital, la pared lateral del seno maxilar y el reborde infraorbitario. Es la fractura facial más compleja de proteger en deporte, y la tercera en frecuencia. Requiere cobertura extensa con diseño que no presione sobre el arco reducido.
Coverage of the zygomatic arch, cheekbone, infraorbital rim and lateral wall of the maxillary sinus. The CT-designed mask creates a bridge over the reduced arch without direct contact on the fracture line, distributing impact forces toward adjacent healthy bone zones.
CT-mandatory: the distance between the mask inner surface and the reduced arch must be ≥4 mm along the full fracture extension. Due to the zygomaticomaxillary complex width (~150 mm), the mask is split into two hemisections (left and right) that fit tightly on the Saturn 4 Ultra 16K 218×122 mm platform, joined over the nasal dorsum. Complex ZMC geometry — greatest benefit of digital workflow vs. thermoforming. Longitudinal reinforcement ribs over the arch.
Mandibular Fracture
The mandible is the most fractured facial bone in hospital settings, though the nose surpasses it in outpatient sport contexts. Sport mandibular fractures predominantly involve the body, angle and condyle. The mandibular mask acts as external protection over intermaxillary fixation or post-ORIF.
Protection of the mandibular body, angle and parasymphyseal region. Designed as a "horseshoe" shell that wraps the mandible inferiorly without interfering with mouth opening during play. The CT-derived design ensures no contact with fracture lines or osteosynthesis hardware.
Due to the mandibular horseshoe width (~140 mm), the mask is printed in two hemisections (left and right) that fit tightly on the Saturn 4 Ultra 16K 218×122 mm platform, joined over the mental symphysis. The biggest challenge is the concave geometry of the mandibular inner face: requires extensive internal support during printing. Minimum clearance over titanium plates: 5 mm to avoid load transfer to the hardware. Free edges rounded R≥4 mm.