Introduction to POP Casts
A broken limb must be stabilized with in a Cast to maintain proper bone alignment, protect it, and support healing. For simple, uncomplicated fractures, recovery time can range from 4 to 8 weeks.
For more severe fractures, it may take several takes months or even a year for a full recovery. Plaster of Paris (POP) Casts are the most widely used products in healing fractured limbs.
This traditional technique, invented in 1851, has many disadvantages and is known to cause serious problems can negatively that a comfort and healing.
The cast can also restrict blood flow, causing discomfort and swelling. As a result, new, lighter materials are being developed for more comfort and better healing.
Introduction to POP Casts
Water Absorbent
A cast made of Plaster of Paris tends to absorb water, causing it to lose its structure and strength over time. As these soak water immediately, they should be wrapped in plastic while bathing.
Application & Removal
Applying a POP Cast can be time-consuming, laborious and messy, typically taking over an hour to complete. Removal of a POP Cast is challenging and sometimes requires cutting blades or scissors.
Bulk Weight
The POP casts are very heavy and bulky so that the user needs a neck brace to hold it most of the times. Due to excess weight, it will be uncomfortable while sleeping and causes pain.
Skin Itchiness
The POP cast will prevent the skin from being exposed to the fresh air. The tight fit of the cast restricts the blood flow to the veins, which can lead to discoloration of skin.
Breaks Easily
The POP cast requires delicate handling, as it is prone to crack- ing or breaking, especially under pressure or impact. Even minor bumps can weaken its structure easily.
Plaster Sores
These are the skin wounds that result from excessive pressure during the plastering process. Sweating for prolonged periods can lead to the development of sores.
Gangrene
Gangrene is a serious and potentially life threatening condition by the death of tissue due to a lack of blood flow. Gangrene can also result from an untreated infection caused by sweat trapped within a cast, leading to tissue damage.
Compartment Syndrome
This is a condition in which prolonged pressure from the POP Cast limits the blood circulation and functioning of the issues. This complication is most commonly observed in fractures of the lower leg and forearm, leading to a loss of limb functionality.
Deep Vein Thrombosis (DVT)
Deep vein thrombosis (DVT) refers to the formation of blood clots in deep veins of the body, due to prolonged restriction of limb movement. Blood clots may obstruct the veins, resulting in redness, swelling, and pain in the affected area.
Compression Neuropathy
Compression Neuropathy is a condition caused by casts that are applied too tightly, leading to compression of the nerves. This will slow down the blood circulation within the nerves.
Muscle Atrophy
Muscle atrophy refers to the natural process of muscle wasting and loss of muscle mass that can occur as a result of using casts over a prolonged period. It can also result in impaired blood circulation within the nerves, which can further compromise the function of the affected muscles.
Skin Irritation
Prolonged, tight plastering may cause skin irritation and rashes. It may also lead to burning sensation and discoloration of the skin.
Dull Appearance
The appearance of POP casts may not be aesthetically pleasing. POP casts may not provide a pleasing aesthetic appearance to the patient, potentially impacting their overall well-being.
One Time Use
The only method for removing a POP cast after a fracture has healed is to cut it off. The repeated reapplication of these casts at each scheduled appointment or X-ray, results in a significant amount of medical waste.
Skin Itchiness
Wearing a wet cast for an extended period can cause discomfort, skin itching, redness, and other forms of skin sensitivity. The complete covering of a cast can limit the individual's ability to scratch or access the skin underneath.
Mental Health
Carrying a POP Cast can be emotionally distressing for an individual. Having a POP Cast can affect a person's mental state, causing discomfort while performing daily activities such as work or attending events.
Skin Atrophy
Skin atrophy is a natural process that can result in the thinning of the inner layers of the skin, leading to a reduction in its overall thickness and volume. Skin atrophy can occur as a result of various factors, including a decrease in exposure to ultraviolet rays, which are a significant source of vitamin D.
Setting Time
After application, it typically takes around 24 to 72 hours for these casts to fully harden and achieve their final form. During this period, the cast remains vulnerable to cracks or damage if not handled carefully.
Bad Odour
POP Casts may emit an unpleasant odour over time due to the accumulation of sweat absorbed within the cast. When the POP Cast cracks or becomes damaged, an unpleasant odor may be emitted, causing irritation.
Pain and Stinging
If a plaster of Paris (POP) Cast is applied too tightly, it can cause discomfort and pain in the affected limb. The warmth inside a cast can cause a stinging or burning sensation, leading to discomfort and skin irritation.
Longer Recovery Period
POP casts can lead to a longer recovery period due to their rigidity and poor breathability. The lack of airflow can cause slow healing. Their weight can also affect muscle recovery, potentially extending the rehabilitation time period.
Introduction 3D Printed Casts
3D Printed Casts is an innovative solution in the field of orthopedic care, offering an upgrade to traditional plaster or fiberglass cast.
Made using 3D Printing technology, it provides a customized fit for each patient, ensuring maximum comfort and support during the healing process.
The lightweight and breathable design of 3D Printed Casts allows for more comfortable in the improved mobility and the hygienecompared conventional casts.
3D Printed Casts can be easily adjusted as swelling changes during the healing process, offering better flexibility. The open design helps with airflow, reducing the risk of skin irritation and infection.
Steps to create 3D Printed Casts
3D Scanning
The 3D Scanning process involves capturing multiple images of the fractured limb firmly supported using a low cost rig.
Images can be captured by any layman even with a 10MP mobile phone camera, making this process the most affordable one.
3D Designing
Using the collected data, a 3D Design for the cast is developed, which includes every aspect from its structural design, locking, vents to its aesthetic features.
To make it more convenient for application and removal, the cast is divided into multiple parts.
3D Printing
Each part of the Cast is 3D Printed sequentially using Polylactic Acid (PLA), a material that is both hypoallergenic and highly durable.
To ensure proper cushioning, the interior surface of the cast is lined with a medically approved padding foam material.
Implementation
The 3D Printed components of the cast are carefully applied on the fractured limb and assembled together, a process that typically takes no more than 10 minutes using the locking mechanism selected by the doctor.
The healing is monitored during scheduled appointments.
Specifications of 3D Printed Casts
Easy Application & Removal
A 3D Printed Cast provides healthcare professionals with easy access to the fractured limb during both the application and removal process. The locking mechanisms can be made to be removeable only by the doctors/ nurses.
Water Resistant
One of the key benefits of using polylactic acid (PLA) material for 3D Printing the Cast is its excellent resistance to water absorption. Patients can bathe, swim, or participate in other water-based activities without the need to remove or modify their device.
Light Weight
The PLA filament used for 3D Printing the cast will be very light weight. The overall weight of an upper limb cast will not exceed more than 200 - 300 grams. The weight can also be calcuated and planned well before.
Customization
One of the key benefits of using 3D Printing technology to create casts is that it allows for highly customized solutions for each individual patient. The process to create a 3D Printed Cast, right from 3D Scanning and 3D Desgining until the application using foam is completely customized.
Well Ventilated
Unlike traditional casts that can cause discomfort and skin irritation due to inadequate ventilation, 3D Printed Casts feature strategically placed holes or vents that allow for natural air circulation.
User Friendly
With its lightweight design, the 3D Printed Cast provides unparalleled comfort during use. Wearing the 3D Printed Cast is a comfortable and delightful experience that the user almost won't even notice it's there.
Skin Friendly
PLA material is an excellent choice for people with sensitive skin as it has been found to be hypoallergenic. Patients enjoy a comfortable experience with PLA material as it is itch and rash free.
Recyclable
The 3D Printed Cast is a sustainable innovation that not only supports patient healing but also enables the material to be recycled and reused. The PLA material is bio-degradable leaving no residue.
Comfortable
The 3D Printed Cast's application process is gentle and non-invasive, resulting in a comfortable fit that won't pressurise the skin. The risk of complications like Compartment Syndrome is greatly reduced with the use of 3D Printed Casts, setting them apart from traditional POP Casts.
Good Aesthetics
In addition to providing superior comfort and durability, 3D Printed Casts also offer the ability to customize the colour, texture, and even add patient-specific details such as their name, making for a truly bespoke experience.
Anti-break or Anti-crack
With the use of PLA, 3D Printed Casts provide a superior level of durability by virtually eliminating the potential for cracks to develop on either side of the cast.
Retained Skin Moisture
The 3D Printed Casts unique design allows for free air circulation around the limb, reducing moisture buildup and keeping the skin hydrated and healthy. If necessary, patients can easily water treat their limb while wearing a 3D Printed Cast.
Access to Injury
With 3D Printed Casts, patients have easy accessibility to the affected area, making it simple to inspect and clean the injury as needed. The unique design of 3D Printed Casts makes routine X-rays and checkups simpler and more efficient for both patients and medical professionals.
Washable
In contrast to traditional casts, 3D Printed Casts can be easily washed and sanitized, ensuring any dirt or marks can be quickly removed for improved hygiene and aesthetics.
Reduced Wastage
Compared to traditional plastering methods, 3D Printing technology is more environmentally friendly as it significantly reduces the amount of waste generated.
Faster Healing
By offering improved support to the affected area, 3D Printed Casts can shorten healing time and enhance the overall healing process for the patient.
Maneuverability
3D Printed Casts offer improved maneuverability, allowing patients greater ease of movement while still providing all the support for healing. Their lightweight design make them more comfortable, enabling better mobility without compromising the stability of the injured area.
Greater Accuracy
Utilizing 3D Scanning technology to create design models of the patient's limb ensures precise alignment of the fracture during the healing process, leading to better outcomes.
User Satisfaction
Wearing a 3D Printed Cast can help users feel more confident in social situations, without feeling self conscious. Moreover, it can make others curious by generating interest and promoting further education and understanding of this innovative technology.
Unique Appearence
3D Printed Casts can be made to reflect the user's personal style and preferences, including the option to select their favourite colours and designs. More than just a functional medical device, it can serve as a unique fashion statement & attracting.
Feel Good Factor
The impressive features of 3D Printed Casts instill a sense of confidence and positivity in the user, enhancing their overall experience and well-being.
Better Fit
With superior fit and comfort, 3D Printed Casts can be worn during events and in work environments, without compromising on mobility or style. Instead of focusing on discomfort or pain, the visually striking design draws attention to its unique form and aesthetic appeal.
Print on Demand
3D Printed Casts can be customized to meet the unique needs of individual users, including any personalization or branding, with the added benefit of on-demand and on-site printing capabilities.
Flexible Design
Crafted with flexibility and adjustability in mind, 3D Printed Casts can be planned to comfortably accommodate swelling and other changes in the limb throughout the healing process, ensuring optimal comfort and support.
Future Scope
Expansion of 3D Casts for Diverse Fractures
Beyond limb fractures, the application of 3D Printed Casts can be extended to other areas of the body such as the skull, waist, and neck, opening up new possibilities for injury management and recovery.
Enhanced 3D Scanning Technology
Automation can be implemented in the 3D Scanning process on the rig, minimising the need for human involvement and allowing operators to focus observation and analysis of the scanning results rather than spending time in capturing images.
Algorithmic Generation of 3D Designs
Efficiently generating cast designs in 3D by utilizing advanced algorithms, optimizing the process and reducing the time needed to produce high-quality designs, also allows for precise customization tailored to each patient’s unique anatomy.
Swift and Efficient Manufacturing of 3D Casts
Increasing the number of 3D Printers in the manufacturing process can significantly reduce production time and boost overall efficiency. Also by applying process optimization techniques, the entire procedure can be completed more effectively, ensuring higher quality output in less time.
Overall Cost Reduction of the 3D Casts
By optimising the manufacturing process and utilising cost-effective machines and materials, it is possible to reduce the overall cost of 3D Printed Casts without sacrificing their functionality, making them a cost-effective alternative to traditional POP casts.
User Centered 3D Cast Manufacturing
By conducting a comprehensive study of the human arm, manufacturers can develop a more efficient framework for 3D Printed Casts that still allows for full customization. Understanding common patterns in arm anatomy helps streamline the initial design process, enabling faster adjustments to individual measurements without sacrificing the personalized fit.
How can you be a part of this Project?
Promote awareness of advancements in 3D Printed Casts by hosting a complimentary 3D Scanning event at your hospital or clinic.
Inspire passionate students to embark on the development of 3D Printed Casts for continued innovation and progress.
Assist us in establishing connections with ortho- pedic doctors and surgeons for the smooth and progressive use of 3D Casts within the society.
Enrich our understanding of various types of fractures by sharing your expertise, insights, and valuable knowledge today.
Support us in devising comprehensive marketing strategies. Implementing them to reach our target audience effectively.
Share your unique & creative ideas from proposing design enhancements to exploring new ways to customize the 3D Casts.
