Embrace

What it does

EmBrace reimagines fracture care with a flat, pre-manufactured PLA mesh that softens in warm water and molds to the arm’s shape. Its breathable, contoured design ensures a precise, lightweight fit, reducing pressure sore, odor, irritation, and infection risk.

Your inspiration

While plaster back slabs are a staple in fracture care for their low cost and efficacy, they often trap heat and moisture, causing discomfort, odor, and infection risk. In pediatric care, children frequently return to A&E before scheduled visits due to itching and poor sleep from wearing the back slab, as well as for broken slab. These issues reveal a mismatch between traditional solutions and modern needs. We asked: how might we redesign the orthopedic back slab to better integrate with today’s lifestyles while preserving its medical value? This question led us to EmBrace, a solution that supports patients across the fracture care journey.

How it works

EmBrace is a flat, pre-manufactured mesh made from PLA, a bioplastic that softens at 60°C. When soaked in an 80°C water bath for 10–15 seconds, it becomes flexible and can be molded directly onto the injured limb for a snug, custom fit. In about 20 seconds, it hardens to provide firm, supportive immobilization for the injured limb. The application involves four simple steps: soften EmBrace in hot water using a sous vide machine, pat it dry using a cloth to prevent burns from residual hot water, mold it carefully onto the arm, then fasten it using adjustable Velcro straps that slide into built-in slits. This allows for a secure, pressure-balanced fit while reducing risks like compartment syndrome and skin irritation common in traditional plaster back slabs. Once EmBrace is no longer needed, it can be reheated, sterilized, and reshaped into its original flat form, allowing for reuse and addressing both sustainability and hospital logistical needs.

Design process

We began with desk research, user testing, and interviews with an orthopedic surgeon to understand back slabs and the fracture care journey. These insights revealed key user pain points and moments of intervention, shaping our design direction. Next, we scoped the project by identifying potential user groups from children to healthcare professionals and focused on wrist and arm fractures, which significantly impact daily activities. We explored various materials, resin, PU foam, TPU, and PLA, evaluating them for comfort, durability, and ease of manufacturing. Support material and fastening systems were tested separately, guided by criteria such as breathability, precise fit, waterproofing, lightweight, and modularity. PLA proved to be the most suitable. We then prototyped rapidly using cardboard and paper, refining the form by testing it on our own arms. CAD modeling and 3D printing allowed us to test moldability, fit, and performance. Using Grasshopper, we created auxetic mesh patterns that flex and adapt while maintaining structural strength. In parallel, we tested strap systems like Velcro and pin-lock mechanisms for comfort and usability. Lastly, feedback from medical students and surgeons helped validate EmBrace’s practicality and feasibility in real-world clinical settings.

How it is different

EmBrace sets itself apart by reimagining the earliest stage of fracture care, an area often overlooked by existing solutions like others in the market. While these designs excel as alternatives to fiberglass casts, they remain costly and aren’t tailored for immediate, short-term immobilization. EmBrace bridges this critical gap. It combines the custom-fit adaptability of others with the fast, mess-free application, while keeping production costs low to rival traditional plaster back slabs. Designed for real-world hospital use, EmBrace fits a range of arm sizes, is reusable, and features an ambidextrous form, reducing storage and logistical complexity while addressing sustainability concerns. More than a cast, EmBrace is a thoughtful, cost-effective, and user-centered response to patient discomfort, clinician workflow, and hospital constraints. It proves that affordability, usability, and empathy can coexist in fracture care.

Future plans

We aim to adapt our back slab design for other body parts, extend user testing to assess long-term wear and comfort, and explore edge cases that our current solution doesn’t yet address. These steps will strengthen the project’s clinical relevance and user impact. We also see potential in evolving EmBrace into a full cast system, which could broaden its applications and further streamline clinical workflows, enhancing efficiency for healthcare professionals while improving patient care.

Awards