Castomize

What it does

Our design is a lightweight, waterproof fracture cast that self-moulds for a precise fit. It solves discomfort, poor ventilation, and bulkiness in traditional casts—offering a breathable, comfortable, and efficient solution for fracture recovery.

Your inspiration

We started exploring this problem when one of our team members broke his arm. He was put into a traditional fibreglass cast and was constantly complaining about how it was itchy and sweaty, where he could not even shower. We found that there were no good alternatives in the market, and this motivated us to explore creating our own better solution.

How it works

a. Heat: Preheat the heating device, then warm the cast for 6 minutes at ~65°C. This process allows the fibres to become malleable. b. Fit: Slide the warm cast over the affected area and secure with in-built clips, adjust for a perfect fit. c. Cool: When the cast starts cooling, the material hardens and takes the shape of the patient's arm. d. Remove: Unclip buckles of cast with removal pin and slide off patient’s arm.

Design process

Our first commercialised product, the Adult Short Arm Cast, began as a 2022 vision to create a breathable, customisable fracture cast that reduces discomfort. Initially, we aimed to 3D scan patients’ arms, but due to pain and time constraints, we pivoted to a self-moulding cast that adapts without scanning. Inspired by fruit wrappings, we focused on breathability after hearing skin irritation complaints with traditional casts. Co-designed with clinical insights, we began trials with a Singapore hospital in 2023, following early tests with healthy volunteers. Over 20 prototypes were developed. Key challenges included Verishore, our internal padding, which initially overheated—later redesigned to be safer and breathable—and the clip mechanism, which evolved from a separate piece to an integrated design based on doctor feedback. The cast’s size was also shortened from full-arm to mid-palm–mid-forearm. Patients requested colours, but due to material limits, we currently offer only white. It uses four materials (two moulding, one padding, one for clips) and takes ~4–5 hours to produce. We're now exploring custom multi-material printers to improve scalability.

How it is different

Traditional fiberglass casts require manual wrapping, water activation, and are non-adjustable once set. They offer poor ventilation, hygiene, and comfort, often becoming loose and bulky over time. Competitors introduce vacuum wraps and heavy heating devices, making their casts cumbersome and unsuitable for space-limited clinics. These casts are non-remouldable and rely on external clips that are hard to secure. In contrast, Castomize uses a compact heater bag to activate its self-moulding, remouldable cast—eliminating bulky machines. It ensures a consistent, secure fit with a seamless fastening system and is made from lightweight, breathable materials. Its water-resistant design allows easy alcohol cleaning, delivering a hygienic, patient-friendly, and space-efficient solution for modern healthcare.

Future plans

We are actively working on expanding our product portfolio to meet a broader range of clinical needs in orthopaedic care. Several innovative solutions are currently in our product development pipeline. In parallel, we are scaling our market presence beyond Singapore. We have begun expansion efforts in Australia and Taiwan, where we are engaging with potential clinical partners and distributors.

Awards

a. Muse Design Award b. Forbes 30 under 30 for Healthcare, Science c. ASEAN Outstanding Engineering achievement