Protection that fits perfectly
Custom scanned and 3D printed cranial plates that shield severe head trauma patients with skull loss, worn discreetly inside a cap.
- 3+
- Items printed
- 2hrs
- Average print time
- PETG
- Filament
External cranial plate
Due to the civil war in Burma, weapon-wounded patients who sustain severe head trauma have sections of their skull damaged. These patients require protective covers for the intracranial tissues to prevent further damage or impact from everyday activities, while they wait to undergo further surgeries to implant a cranial plate at a Thai hospital. Mae Tao Clinic’s physiotherapy team brought this to the attention of HFA-BCMF’s 3D team. In collaboration with an intern from Queen's University in Canada, we developed a personalised solution using advanced 3D scanning technology. The team scans each recipient's head using a Revo Scan, then digitally edits the scan to create a custom-moulded cover that fits precisely to the individual's unique head shape. After printing, foam padding is added to the skull cover for comfort and shock absorption. The cover is then attached to the inside of a cap using Velcro, which allows it to be concealed discreetly while keeping it securely in place. Recipients can now move through daily life with essential head protection, greater safety, and restored confidence.
Product photos
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Recipient stories
Too
Age 21
Injury
“This cover makes me feel secure. I can go out without fear or shame.”
In December 2024, Too, a 21-year-old man from Burma, lost nearly half of his skull due to an injury. He was brought to a hospital in Thailand, where he underwent emergency surgery. Following his recovery, he was referred by a partner organisation to BCMF for an assessment. BCMF team worked with a student from Queen’s University in Canada and designed a 3D printed skull plate secured inside a baseball cap. Too’s head was measured and scanned, and he received one of our custom 3D-printed skull plates and two caps, which has profoundly changed his daily life.
”I'm so happy now”, he said. “Before, people would stare and harass me because of how my head looked. I was afraid to go outside, especially during the rainy season, due to the risk of slipping and falling. This cover [skull plate with cap] makes me feel secure. I can go out without fear or shame.”
Tun
Age 27
Injury
“It gives me confidence to walk. I am excited to keep improving...”
Tun, a 27-year-old man from Burma, sustained a severe injury, including losing a third of his skull in May 2025. After receiving treatment in Thailand, he was referred to BCMF for a prosthetic arm and skull plate. Previously in a wheelchair due to his leg injury, Tun began walking using a crutch, and thus the skull cover became essential for his safety. Walking without head protection caused him significant anxiety due to the risk of falling or sustaining further trauma. The skull plate has allowed him to focus on rehabilitation and rebuilding his independence, giving him renewed motivation to continue improving. The skull cover now provides vital protection while he waits for a more advanced, permanent medical solution that will offer protection beneath the skin.
Tun shared, “Before I received the skull cover, I felt nervous and unsafe every time I tried to walk or go outside. I was always worried that if I fell or hit my head, I could die. Now, with this skull cover, I feel much more secure. It gives me confidence to walk. I am excited to keep improving and working towards my recovery. Thank you very much for supporting me during this time.”