Plaster casts have been widely used in the treatment of fractures, but their limitations—including weight, fragility, and susceptibility to water damage—have led to the development of alternative solutions. Cast21 is a polymer-based arm brace designed as a waterproof, breathable, and structured support system for fracture recovery.

Material Innovation and Structural Design
Cast21 utilises a pre-formed, open-lattice structure that replaces conventional plaster casting. The brace is fitted around the injured limb and injected with a polymer resin, which hardens within minutes to provide the necessary support. This process eliminates the need for traditional setting and drying times associated with plaster.

The open structure facilitates ventilation, reducing skin irritation and moisture build-up. The polymer material is water-resistant, enabling users to maintain regular hygiene practices, including showering and swimming, without affecting the brace’s functionality.

Applications in Product Design and Medical Wearables
The design of Cast21 presents applications in medical wearables and product design, particularly in the development of customisable, patient-specific supports. The structural framework optimises material use while maintaining mechanical stability.

The modular nature of the brace allows for variations in size, colour, and form, providing an adaptable alternative to traditional immobilisation methods. The approach aligns with developments in personalised medical devices and advances in polymer-based healthcare solutions.

Sustainability and Material Efficiency
The materials used in Cast21 provide potential recyclability advantages over conventional plaster, which is typically discarded as medical waste. The polymer formulation reduces material consumption compared to solid plaster structures, aligning with sustainable manufacturing principles.

Additionally, the reduced weight and efficient production process contribute to lower resource consumption and transport emissions. These factors position Cast21 within ongoing discussions on circularity and material innovation in medical applications.

Source: DesignWanted.com
Photos: Cast21