A novel low cost manufacturing method for bone replicas is developed in order to provide cross sectional geometry for 3-D modeling.A Finite Element Analysis (FEA), based on this geometry, is used to predict stress distributions in the radius with and without an internal fixation device attached.The changes in stress distribution under tensile and torsional loads are quantified and agree well with predictions in current literature where more expensive modeling techniques are used.Normal stresses near the radial cortex are seen to be higher with the fixation device, however stress gradients are substantially steeper resulting in lower tensile stresses with decreasing as radial distance.Shear stress minimum values increase with the presence of the plates and do not reverse direction as is the case with the un-plated radius.Stress shielding effects due to the plates and stress concentrations due to the holes are observed to significantly affect stress magnitude and distribution in the radius bone with a fixation device.The results from this research support the conclusion that fixation devices leave bones more susceptible to future injury.