What it does
Morphopaedics is a modern alternative to traditional plaster casts, designed to solve discomfort, poor hygiene, and inefficiency in fracture care. Its lightweight, breathable, and adjustable design improves patient recovery, reducing strain on the NHS.
Your inspiration
After breaking my back in a hockey match at 17, I spent months immobilised in a wheelchair and in rehab, gaining first-hand insight into the discomfort, frustration, and limitations of traditional orthopaedic casts. That experience stayed with me and, as a design student, I saw an opportunity to turn it into meaningful innovation. Morphopaedics was born from empathy and a desire to improve recovery - not just for patients like me, but to support overstretched healthcare systems. This cast rethinks immobilisation to prioritise comfort, hygiene, and clinical efficiency.
How it works
Made from a durable, radiolucent polymer (Nylon 6/6 GF), the cast allows X-rays to pass through - so it never needs to be removed for imaging. Its open lattice design improves ventilation, reducing skin irritation, sweating, and odour. The cast features micro-adjustable straps and a modular fit system, which can accommodate swelling or anatomical changes without needing a full replacement. It can be applied quickly without water or specialist tools, and incorporates the opportunity for patient self-removal. The application process is much quicker and allows every cast to be moulded to each patient. Morphopaedics is also water-resistant, meaning patients can shower without needing protective covers as well as excercise as sweat can be washed off. Its strength and stiffness have been engineered to provide immobilisation, while still being lighter and more comfortable than traditional options.
Design process
The design process for Morphopaedics began with personal experience and extensive user research, including interviews with patients, orthopaedic clinicians, and physiotherapists. Early concepts focused on improving comfort and hygiene, while addressing NHS workflow challenges. Using an agile methodology, the project evolved through fast iterations of prototyping and feedback loops. The first prototypes were rigid, 3D-printed shells that tested fit and breathability. Feedback revealed issues with pressure points and adjustability. Later versions introduced mouldability and a micro-adjustable fastening system to allow for swelling and limb variation. Finite element analysis was used to optimise the structure, balancing strength with ventilation. Each sprint cycle involved building, testing, and evaluating - refining the design through clinician-led usability sessions. A key breakthrough came with using a radiolucent polymer, allowing the cast to remain on during X-rays. The latest prototype is water-resistant, tool-free to remove, and fits a wide range of patients with fewer sizes. With extremely iterative development, the cast continuously evolved with real-world feedback, resulting in a solution that supports patient comfort, staff efficiency, and healthcare sustainability.
How it is different
Morphopaedics stands out by combining comfort, clinical efficiency, and sustainability in one cast. Unlike traditional plaster or fibreglass casts, it’s radiolucent, meaning it doesn’t need to be removed for X-rays, saving time and reducing disruption to healing. Its open, breathable structure prevents skin irritation, sweating, and odour - common problems in standard casts. The micro-adjustable fit adapts to swelling or anatomical changes, reducing the need for replacements. It’s lightweight, water-resistant, and can be applied or removed without specialist tools. Most similar products either focus on immobilisation or comfort - not both. Morphopaedics delivers both, while also fitting seamlessly into NHS workflows, offering a reusable, cost-saving alternative that benefits patients and providers alike.
Future plans
Morphopaedics is now entering final prototyping and early clinical testing and regulatory preparation, with plans to launch NHS pilot trials and secure CE/UKCA certification. A UK design has been registered to protect the innovation, with international patent filings being considered. The next steps include biomechanical and biocompatibility testing, NHS trust partnerships, and applying for Innovate UK and NIHR funding. The long-term goal is to scale Morphopaedics across the NHS and private sector, expand to other fracture types, and explore reusable, sterilised models to reduce waste and support sustainable healthcare.
Awards
Morphopaedics has won two prestigious awards at New Designers 2025: New Designer of the Year – the top prize awarded by the Business Design Centre. Design Innovation in Plastics Award – recognising the most innovative use of plastic in a product.
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