When Charlotte Latin’s reigning state champion wrestler, Davis Jones, broke his hand 2 weeks before this year’s state tournament, he was devastated. The question was not whether the injury could be stabilized – modern orthopedic surgery has answered that. The question was whether he could compete safely while protecting the injury and maintaining enough function to make another run at the title.
This is the story of how OrthoCarolina surgeons and DME Providers collaborated with PROTECT3D engineers and combined their expertise to help Davis Jones return to the mat for his third state title.
The Injury and the Time Pressure
Davis sustained a spiral fracture of the second metacarpal shaft in his hand. The injury occurred only 2 weeks before the tournament, which meant there was virtually no recovery window. Surgical stabilization was essential, and precise return-to-play protocols, including bracing, would need to be implemented. Davis was lucky to be taken care of by the orthopedic group that takes care of the Carolina Panthers and Charlotte FC, so the clinicians knew just what to do.
Surgical Stabilization and Post–Op Needs
Davis underwent a successful ORIF surgery to stabilize the fracture by a leading hand surgeon, Dr. Glenn Gaston, at OrthoCarolina. Dr. Gaston is no stranger to elite athletes and their recovery needs, but this use case would be among the fastest he had ever cleared someone for return to competition. In order to do so, he knew right where to turn to make this possible: PROTECT3D.
Dr. Gaston sent Davis to OrthoCarolina’s Durable Medical Equipment (DME) team to have his hand 3D scanned on February 3rd, 2026. PROTECT3D’s engineers, including a team member with a Jiu-Jitsu background familiar with the requirements of combat sports, were able to design a product fit for wrestling and return the brace on Wednesday afternoon, just 24 hours later. Davis wore it during his practices that week and was ready for the state tournament the next week.
Why Standard Protection Wasn’t Enough
Traditional hand braces are designed for stabilization during daily activities rather than high‑contact sports. Plaster casts can be heavy, restrict movement, and even increase the risk of further injury, while off‑the‑shelf braces tend to be bulky and uncomfortable. Wrestling imposes unique demands, requiring the flexibility to grip and post, as well as the ability to absorb impact without excessive padding. This is exactly why Davis’s elite team of clinicians and coaches sought a custom solution. They needed a brace that fit the exact contour of Davis’s hand, provided rigid support at the fracture site, minimized bulk, and gave him the movement he needed to return to competition confidently. To check all these boxes, they knew PROTECT3D was their best move forward.
Building a Custom Solution with PROTECT3D
PROTECT3D’s process uses a rapid 3D scan of the injured anatomy and patented technology to design the product onto that scan. Using a smartphone scanner, the team obtained a model of Davis’s hand with submillimeter precision in seconds. Engineers then translated that scan into a custom bivalved clamshell that puzzle-pieced together for a perfect, fully encompassing fit that allowed full range of motion in the fingers and wrist. Because the design was digital, PROTECT3D could collaborate quickly with the clinical team, adjusting thicknesses and other design decisions based directly on feedback. PROTECT3D’s proprietary process produced the final brace in time for the State Championships, with the protection needed to allow Davis to continue to perform at the high level he was used to before the injury.
Returning to Play and the Outcome
With his custom brace, and thanks to his mother for driving to PROTECT3D’s headquarters in Durham, NC, for a rapid turnaround of the product, Davis resumed training almost immediately. The custom-fit device protected Davis from further injury and the foam exterior protected opponents from harm. By the time the state championship arrived, Davis and the PROTECT3D team were able to fine-tune the design and provide an additional version of the product that fit perfectly. Davis used it and won the tournament, capturing his third consecutive state title!
In his words, the brace “gave me the chance to compete while protecting my broken hand,” which is a testament to athlete-centered engineering and clinical care.
Lessons for Clinicians and Engineers
This case illustrates that custom orthotics are not just about comfort; they can be the difference between sitting out and competing. The ability to scan, design, and print a precision brace on an accelerated timeline can transform the management of acute injuries. The collaboration among surgeons, DME Providers, athletic trainers, and engineers ensures that protection does not come at the expense of performance. As Davis’s outcome shows, when clinicians and engineers work together, athletes can return to play safely and confidently.
Acknowledgements
Special thanks to OrthoCarolina’s Dr. Glenn Gaston and Dr. Carroll Jones; to OrthoCarolina’s DME Team, Sarah Reed, Kristen Cates, and Matthew Lucas, who guided the rehabilitation and supported Davis’s return. This collaboration embodies PROTECT3D’s mission: athlete-first innovation that delivers precision fit, fast turnaround, and real clinical partnership.