Cell-Cast

A modular cast system using thermoplastic materials to enhance patient comfort

Self Project

Cell-Cast is a modular, patient-friendly cast system made from low-temperature thermoplastic. It is lightweight, breathable, and waterproof, easily molded to fit injuries, and can be safely removed with pliers—providing comfort, hygiene, and personalized support throughout the healing process.

Results

2017 International Design Excellence Awards (IDEA) - Finalist

Problems of the Current Casting Method

After a bone fracture, proper rest and support are essential for healing. Plaster and fiberglass are the most common cast materials, but both have drawbacks. When moisture penetrates and dampens the protective cotton layer, it becomes difficult to dry, causing odor, itching, and skin irritation, which leads to patient discomfort. Additionally, once the injury heals, casts are removed using a specialized saw. This process can be intimidating, especially for children, who may become frightened by the sound and sight of cutting. These issues highlight the need for a more comfortable and effective bone treatment solution.

Not waterproof / Itching / Scary removing process by sawing

Experimental process

To create a cast material that is easily molded yet rigid enough to support fractured bones, I explored low-temperature thermoplastics. This material softens when heated, allowing precise molding, and hardens upon cooling to provide rigid support, making the process reversible. It is non-toxic and reusable, offering a promising alternative to traditional casting methods.
Two key insights emerged from material experiments:

Some low-temperature thermoplastics have elastic memory and retain shape without slumping when reheated.
Preforming a tube shape allows the injured limb to slide in easily, after which the tube can be molded into a personalized cast.

Lighter, More Breathable, and Waterproof for Patient Comfort

Cell-Cast is a modular cast system using low-temperature thermoplastic to create comfortable, customized casts. Its hollow structure exposes most of the skin and is waterproof, allowing patients to wash or even swim, while preventing heat and sweat buildup that causes discomfort in traditional casts. By assembling multiple Cell-Cast units, orthopedic doctors can create different sizes and forms to match the patient’s injured area. The material softens with heat for easy molding and hardens upon cooling to securely support the bone.

How It Works

The flat thermoplastic material can be heated and shaped into a tube cast that conforms precisely to the injured area. Once cooled, it becomes rigid, providing strong support for healing bones.

Its hollow design enhances breathability and reduces discomfort, while water resistance allows patients to shower or swim without compromising the cast.

Removal is simplified using pliers, eliminating the fear associated with saw-based cast removal.

Page updated

Google Sites

Report abuse