The plaster/fibreglass orthopaedic cast has existed in various forms for over 200 years. While its efficacy informs its longevity, the solution has drawbacks like being uncomfortable to wear and tedious to apply/remove. Singapore-based startup Castomize has introduced a 4D-printed cast that improves on the traditional option across every metric for what may eventually be the new industry standard in orthopaedic casting.

Castomize’s secret sauce is 4D printing. The cast is first 3D-printed in the startup’s proprietary polymer, which is hard and rigid at room temperature. However, when heated to around 55°C, it softens to become more malleable. This change in physical properties is 4D printing’s fourth, final dimension: time. Applying Castomize’s cast is thus a simple process of heating it, then shaping it around the limb to be immobilised before letting it cool down and harden again.

Castomize’s cast matches plaster/fibreglass ones in terms of efficacy while improving on them by being light, open, waterproof, infinitely re-adjustable, and easy to apply/remove. These features translate to better care from clinicians and an improved healing journey for the patient. Indeed, various organisations have already noted the potential for Castomize’s solution to improve fracture care significantly, and the startup is already securing sales contracts regionally as it transitions to revenue generation.

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