TissueDB/Simulators/Tibial Shaft Transverse Fracture Simulator
The Tibial Shaft Transverse Fracture Simulator is a low-cost, gender-specific orthopedic surgical simulator — built from open-source, locally reproducible 3D-printed bone models and everyday cellophane — for practising Schanz screw placement in the external fixation of adult tibial shaft transverse fractures.[1]
| Field | Details |
|---|---|
| Features and Basic Operation | The learner clamps both 3D-printed fragments 2–3 mm apart but otherwise aligned, like a fracture with restored angulation and rotation; drills 4.5 or 5.0 mm self-drilling Schanz screws under power through the near cortex and by hand into the far cortex; inspects alignment through the transparent cellophane; then removes the fragments and measures drill-trajectory angles on the exposed cross-section for self-assessment. |
| Current Development Status | Third-party built and tested (expert-surgeon design survey; user testing in Nigeria); not yet formally validated for skills transfer or clinical outcomes |
| Estimated Build Time and Cost | Not stated in source |
| Specialized Tools and Equipment | Powered orthopedic surgical drill (compatible with 4.5 or 5.0 mm self-drilling Schanz screws); chuck key; 4.5 or 5.0 mm self-drilling Schanz screws |
| Version | Version 1 |
| Development Team Contact Information | Tibial Fracture Fixation Project — Global Surgical Training Challenge; co-leads Habila Umaru, MBBS FWACS, and Julielynn Wong, MD MPH. Funded by an Intuitive Foundation grant. |
Tissues
| Tissue | Qty | Material | Cost | Notes |
|---|---|---|---|---|
| Cortical bone (proximal tibial shaft) | 1 | 3D printed PLA bone model (Model 1) | $5–10/model | Proximal fracture fragment; semi-engraved model number, gender symbol, and drilling direction arrows on base. |
| Cortical bone (distal tibial shaft) | 1 | 3D printed PLA bone model (Model 2) | $5–10/model | Distal fracture fragment; female tibial bone models under revision. |
| Periosteum | 1 roll | Clear cellophane wrap | $3–10/roll | Simulates the overlying periosteum; its transparency permits visual inspection of alignment and far-cortex integrity for self-assessment. |
Structural Parts
| Part Name | Qty | Material | Cost | Notes |
|---|---|---|---|---|
| 2-in-1 multifunction bench vise clamp | 2 | Aluminium alloy, 360-degree rotary | — | Suggested per user feedback. Easier to use and cheaper overall than table clamps + G-clamps. Imported; allow 2 weeks delivery. |
| G-clamps (alternative) | 4 | Standard | $5–7 each | Alternative configuration: use 4 G-clamps with 2 standard vise clamps if 2-in-1 clamps unavailable |
Build Instructions
Download the source STL files before preparing the print files:
- Model 1 — proximal fragment (25 June 2022) (file details)
- Model 2 — distal fragment (19 May 2022) (file details)
For general file preparation, see working with PLA and STL files. For this model's required print settings and orientation, follow the developers' print-file preparation instructions.[2]
Phase 1: Simulator Assembly
Source: Setup video at https://youtu.be/NTZxXlC3PBQ
Step 1. Position two vise clamps on a table approximately 25 cm apart and open the jaws of each vise clamp.
Step 2. Wrap clear cellophane around the 3D Printed Adult Tibial Bone Models 1 and 2 held by an assistant.
Step 3. Distract the proximal and distal fragments of the wrapped simulator by 2–3 mm.
Step 4. Place Model 1 (the proximal fragment) into the left vise clamp and Model 2 (the distal fragment) into the right vise clamp. Each vise attachment should be centred on the platform overlying the threaded screw (or exposed threaded screw) that connects the jaws of the vise clamp.
Step 5. Use the two vise attachments of the simulator to gauge the distance between the left and right vise clamps. Adjust the position of the vise clamps and then secure each vise clamp to the table.
Step 6. Turn each vise handle until the jaws are clamping each model securely. Confirm that the proximal and distal fragments are distracted by 2–3 mm but are otherwise properly aligned to simulate a fracture with restored angulation and rotation.
Step 7. The simulator simulates the left tibia. Confirm proper orientation by checking the two semi-engraved drilling direction arrows on the base of each model. The drilling direction arrows of both models should point medial-to-lateral.
Step 8. Push on each model near the fracture line in a medial-to-lateral and anterior-to-posterior direction to verify stability before drilling. If the model moves, re-tighten all handles of each vise clamp for a stronger grip.
Phase 2: Drill Assembly and Testing
Any powered orthopedic surgical drill that is compatible with 4.5 or 5.0 mm diameter self-drilling Schanz screws can be used for this skills training module.
Step 1. Obtain a powered surgical drill and chuck key (e.g., Arbutus Medical HEX Drill Kit) and a 4.5 or 5.0 mm self-drilling Schanz screw.
Step 2. Follow the surgical drill manufacturer's instructions to assemble the drill and insert a 4.5 or 5.0 mm self-drilling Schanz screw using the chuck key. If using the Arbutus Medical HEX Drill Kit, follow the video instructions.
A sterile person is NOT required to assemble the drill for simulation training.
Step 3. Test the surgical drill by squeezing the on/off trigger to confirm that the drill is ready for use. If using the Arbutus Medical HEX Drill Kit, push the forward drilling direction switch on the right side of the drill for clockwise rotation. The Schanz screw tip should rotate clockwise when pointing away from the operator.
References
- ↑ Tibial Fracture Fixation training module, Global Surgical Training Challenge. Source training module: build and operating instructions for this simulator.
- ↑ Medical Makers. Prepare 3D Print Files, Adult Male Tibial Bone Model 3D Files table, Models 1 and 2. Appropedia.
Sources consulted for this page but not cited at a specific claim:
- 3D-printed medical bone model pricing via on-demand services (May 2026): typical $5–10 USD per model on Craftcloud and Treatstock platforms ($0.10–$0.50 per cubic centimeter for FDM PLA).
- Clear cellophane wrap retail pricing, Walmart product listings (May 2026): American Greetings 30 sq.ft. $3.48 USD; Tripumer 1 Roll $10.00 USD. Available at walmart.com/c/kp/cellophane-wraps.
- Heavy Duty G-Clamp 4 in / 100mm 4-pack retail pricing, Amazon listings (May 2026): typical 4-pack price $18–28 USD for 4 units. Available at amazon.com.
| Alternative names | Tibial Fracture External Fixation Simulator Schanz Screw Placement Simulator External Fixation Simulator External Fixation Trainer Tibial Fracture Fixation Simulator Tibial Shaft Fracture Model |
|---|
| Authors | Arturopelayo, Julielynn Wong, Medical Makers |
|---|---|
| License | CC-BY-SA-4.0 |
| Cite as | Arturopelayo, Julielynn Wong, Medical Makers (2021–2026). "TissueDB/Simulators/Tibial Shaft Transverse Fracture Simulator". Appropedia. Retrieved October 3, 2026. |