TissueDB/Simulators/Orthoplastic Reconstruction Simulator
The Orthoplastic Reconstruction Simulator is a low-cost long-bone fracture phantom, built from locally available materials, for training external fixator (Ex-Fix) placement.[1] It represents a fractured long bone with a medullary cavity: two plastic-pipe segments packed with sand and vegetable oil sit either side of a fracture gap, wrapped in sponge for the soft-tissue envelope and felt for skin, all mounted on a wooden base. The trainee drills fixator-pin holes through the pipe cortex and applies an external fixator across the fracture. Base construction follows the AmoSmile Physical Simulator design, and all materials can be substituted for similar items sourced locally. Developed as part of the Orthoplastic Reconstruction training module within the Global Surgical Training Challenge by the AmoSmile team.
| Field | Details |
|---|---|
| Features and Basic Operation | The trainee drills fixator-pin holes through the cortical pipe (drill bit 1 mm smaller than the Schanz pins) and applies an external fixator across the 0.5 cm fracture gap. The sand-and-oil medulla gives drilling resistance; the sponge is the soft-tissue envelope and the felt is skin. |
| Current Development Status | First-pass developer prototype — built and described by the developers; not independently tested, and no skills-transfer or clinical evidence reported. |
| Estimated Build Time and Cost | $10–20 (estimated) |
| Specialized Tools and Equipment | Hole punch, drill and drill bit (1 mm less than Schanz pins), external fixator kit |
| Version | Version 1 |
| Development Team Contact Information | AmoSmile team, Global Surgical Training Challenge (Orthoplastic Reconstruction module). The module source names no individual researcher email or institutional postal address. |
Tissues
| Tissue | Qty | Material | Cost | Notes |
|---|---|---|---|---|
| Skin | 1 | Felt | — | Outer skin layer; anchored to the board with elastic bands looped through punched holes. |
| Soft Tissue | 2 | Sponge | — | Two cushion layers — one beneath the bone segments, one above. |
| Bone (cortex) | 2 | Plastic Pipe | — | Cortical pipe segments either side of the fracture gap. |
| Bone Marrow (medulla) | 2 | Sand + Vegetable Oil | — | Compacted sand–vegetable-oil fill inside each pipe segment. |
Structural Parts
| Part Name | Qty | Material | Cost | Notes |
|---|---|---|---|---|
| Wood Board | 1 | Wood | — | Build base; carries the side pegs and screw fixation. |
| Screws | 2 | — | — | One per lateral pipe end, driven through the pipe wall into the board. |
| Super Glue | 1 | — | — | Used only if the sponge edges lift after placement. |
| Pins or Nails | 10 | — | — | Side pegs along the long edges; anchor the elastic bands. |
| Elastic Bands | 10 | — | — | Loop through the felt holes; anchor to the side pegs. |
Build Instructions
Phase 1: Base and Bone Assembly
Step 1. Build the wooden base following the AmoSmile Physical Simulator design: use a 50 cm × 20 cm wooden board and drive 10 pins or nails along the long sides as pegs.
Step 2. Cut 2 segments of 15–20 cm from a 3 cm-diameter, 50 cm plastic pipe. Pack each segment with a mix of sand and vegetable oil, compacted as tightly as possible to simulate the bone medulla.
Step 3. Place a 45 cm × 10 cm piece of sponge onto the wooden board.
Step 4. Lay the 2 pipe segments onto the sponge, leaving a 0.5 cm gap between the pipe ends to represent the fracture site.
Step 5. Secure each bone end to the board: drive 1 screw through each lateral pipe end, through the pipe wall and into the board.
Phase 2: Soft Tissue and Skin
Step 6. Lay a second 45 cm × 10 cm piece of sponge over the pipes and the fracture gap. Glue the edges if the sponge lifts.
Step 7. Cut a 45 cm × 10 cm piece of felt.
Step 8. Punch 5 holes on each long side of the felt (10 holes total).
Step 9. Lay the felt over the sponge that sits on top of the pipes.
Step 10. Attach the felt to the board by looping elastic bands through the punched holes and securing them to the side pegs.
References
- ↑ Source: Orthoplastic reconstruction/Physical Simulator — the physical simulator of the Orthoplastic Reconstruction training module, part of the Global Surgical Training Challenge, developed by the AmoSmile team; Appropedia, CC BY-SA 4.0.
| Alternative names | Orthoplastic reconstruction Physical Simulator |
|---|
| Authors | Arturopelayo |
|---|---|
| License | CC-BY-SA-4.0 |
| Organizations | Global Surgical Training Challenge, AmoSmile |
| Cite as | Arturopelayo (2026). "TissueDB/Simulators/Orthoplastic Reconstruction Simulator". Appropedia. Retrieved July 15, 2026. |