Radiographic Healing and Observed Complications Following Light-Cured Polymer Immobilization: A Retrospective Cohort Study of 108 Patients

Purpose: Traditional plaster and fiberglass casts remain widely used for fracture immobilization but are associated with recognized challenges, including skin irritation, hygiene limitations, and distress during cast removal, particularly in pediatric populations. Light-cured polymer immobilization (LCPI) systems have been introduced as an alternative method of fracture support. The primary objective of this study was to describe radiographic healing and alignment outcomes among patients treated with an LCPI system. Secondary objectives were to document skin- and device-related events and to identify any unplanned removals or subsequent re-interventions. Methods: A 6-month retrospective cohort study was conducted involving 108 consecutive patients treated with an LCPI system between January and June 2025 at a single orthopaedic clinic. Clinical and radiographic records were reviewed to extract demographic information, injury characteristics, treatment details, immobilization duration, healing outcomes, alignment status, and recorded adverse events. Outcomes were summarized using descriptive statistics. Results: Immobilization was applied for 104 fractures (96.3%), three sprains (2.8%), and one elbow dislocation (0.9%). The cohort (76 males, 32 females; mean age: 13.4 years; range: 4–53) demonstrated radiographic union or progression toward union among fracture cases with available follow-up imaging. Mean immobilization duration was 29.2 days (SD: 6.2; range: 10–48). Alignment at device removal was documented as anatomic or near-anatomic in 103 of 104 fractures (99.1%) based on treating clinician assessment (99.1%). Device breakage was documented in 12 cases (11.1%), of which 3 required additional immobilization. Two patients (1.9%) experienced mild cutaneous reactions that resolved with conservative management. No severe device-related complications were documented. Conclusions: Healing outcomes and recorded adverse events were consistent with expected clinical patterns for this patient population in this descriptive retrospective cohort of patients treated with an LCPI system. These findings provide descriptive real-world data regarding clinical utilization and short-term outcomes in selected patients. Prospective comparative studies are needed to further define effectiveness, safety, cost considerations, and broader applicability across diverse fracture populations.