Singapore's 3D-Printed Cast Is Waterproof and Itch-Free

Anyone who's broken an arm knows the misery isn't just about the pain. It's the weeks of itching under a rigid cast you can't get wet, making every shower a plastic-bag ordeal.

Now hospitals in Singapore are offering something better. Castomize, a local startup, has created an open 3D-printed cast that's comfortable, waterproof, and adjustable.

The process is surprisingly simple. Doctors heat the cast until it becomes soft and flexible, wrap it around the injury, and clip it together with built-in buckles. As it cools, it hardens into place perfectly molded to the patient's arm.

Compare that to traditional casting, which requires 10 different steps and multiple materials. Mistakes happen easily when wrapping too tight or too loose, leading to pressure injuries and painful complications. Many patients end up needing a completely new cast, forcing another clinic visit and added costs.

The new design solves that problem. If adjustments are needed as swelling goes down or healing progresses, doctors can simply unclip the cast, reheat it, reshape it, and put it back on. No waste, no starting over.

The Ripple Effect

While the 3D-printed cast costs 30% to 50% more to produce, hospitals are actually saving money overall. One Singapore hospital has seen average cost savings of 25% thanks to fewer remakes and faster application times. Doctors spend less time on each patient, and patients avoid repeat visits.

The benefits go beyond money. Patients can shower normally, swim, and scratch their skin when it itches. The open design also means better airflow, reducing skin problems that plague traditional casts.

The technology started as a student project at Singapore University of Technology and Design in 2017. Cofounder Johannes Sunarko revisited it for his master's thesis in 2021, then teamed up with Eleora Teo and Abel Teo to launch the company.

After clinical trials proved it worked just as well as traditional wrist casts, Singapore approved it as a medical device last year. Australia, South Korea, and Taiwan have also given approval. The company is now working on FDA clearance for the United States and European certification.

Castomize plans to eventually sanitize and reuse the casts for different patients, making them even more sustainable. The company calls their approach "4D printing" because the cast changes shape over time after leaving the printer.

Breaking a bone will never be fun, but at least the recovery just got a whole lot more bearable.