BreakCheck

What it does

BreakCheck is a mechanical diagnostic patch that visually indicates hidden bone fractures using printed strain patterns. It solves the challenge of diagnosing fractures in areas without access to imaging or electricity.

Your inspiration

I once saw a news report where an injured child in a remote village was treated for a sprain, only to later discover he had a fracture that healed incorrectly. That moment made me question why such a basic diagnosis still depends on expensive machines. As a mechanical and aeronautical engineering student, I’ve studied how aircraft detect internal stress using strain sensors without opening anything up. That sparked a thought—could we use similar principles on the human body? That idea became BreakCheck: a low-cost, power-free patch designed to detect fractures where imaging devices can’t reach.

How it works

The patch is made of a paper sheet printed with a special pattern of lines using stretch-sensitive ink that changes shape or alignment when stretched. When placed on the skin over a suspected injury and gently flexed using hand pressure, the patch responds to how the surface deforms. If the bone is intact, the pattern stretches smoothly and evenly. But if there’s a fracture, the bone causes uneven movement beneath the skin, making the pattern visibly warp, shift, or even change colour in certain areas. This visual change signals a possible break. The patch also includes a simple colour and shape guide to help users interpret the result quickly without needing specialist training. Because it’s entirely mechanical and passive, BreakCheck requires no electricity, batteries, or complex equipment—making it ideal for rural clinics, emergency responders, or disaster zones where X-ray machines or imaging devices aren’t available.

Design process

I began with the concept of using printed strain patterns inspired by aircraft wing sensors to detect fractures. Through extensive research, I explored different materials like flexible inks and mechanochromic paints that change color when stretched, aiming for clear, easy-to-interpret visual feedback. I studied how skin and muscle movement might affect sensor accuracy and focused on designing strain patterns sensitive enough to detect subtle differences caused by fractures. My initial designs featured simple radial and fractal patterns intended to highlight uneven strain caused by bone breaks. To ensure consistent and repeatable readings, I planned a soft mechanical frame to apply gentle, controlled pressure on the limb during use, mimicking how doctors physically test for fractures. Although I have not yet built a physical prototype, this research and iterative design thinking have helped me refine the concept, emphasizing low-cost, passive materials and straightforward application suitable for remote or resource-limited settings. I have completed making the online prototype, the CAD model using SolidWorks for reference to see how the patch should look and perform in real time. With limited resources I believe I have made the best possible outcome.

How it is different

BreakCheck is unique because it combines low-cost, passive materials with a simple mechanical method to detect bone fractures without electricity, imaging equipment, or specialist training. Unlike traditional fracture diagnosis that relies on X-rays or expensive electronic devices, BreakCheck uses printed strain patterns that visibly change when placed over a fracture and flexed gently. This mechanical, colour-changing approach is inspired by aerospace strain sensors but adapted for human anatomy in a disposable patch form. Its simplicity, portability, and affordability make it ideal for use in remote or resource-poor settings where access to medical imaging is limited or unavailable. No other product offers this combination of accessibility, ease of use, and immediate visual feedback without the need for power or complex tools. And X-rays are used for detection of broken bones, which is harmful in the long run. Hence my product tackles that issue too.

Future plans

Next, I plan to develop physical prototypes using flexible materials and mechanochromic inks to test BreakCheck’s sensitivity and accuracy in detecting fractures. I will collaborate with medical professionals for real-world feedback and validation. Simultaneously, I aim to explore partnerships with NGOs and healthcare providers to distribute the patch in low-resource areas. Long term, I hope to scale production to make fracture diagnosis accessible worldwide, reduce reliance on harmful X-rays, and improve early treatment outcomes in remote and emergency settings.

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