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Removable Cast

Removable Cast. Background of the Problem. When someone breaks a bone, their broken bone is placed in a protective cast that can not be removed.  After a while the skin under the cast starts to itch and smell. Problem and Goal Statement.

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Removable Cast

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  1. Removable Cast

  2. Background of the Problem • When someone breaks a bone, their broken bone is placed in a protective cast that can not be removed.  After a while the skin under the cast starts to itch and smell.

  3. Problem and Goal Statement • Design a removable cast to go on a forearm that can be easily taken off and put back on by the wearer.  

  4. Problem Solving Approach • The idea is to have a 3D scanner scan the broken arm and send the data to a 3D printer that will create a cast that is custom fit for the person who broke their arm.   • The cast must be comfortable, easy to take off and put back on, and not be bigger than a traditional cast. It must also protect the injury as well as a traditional cast. • The design will have an inner shell, which is custom molded with a 3D printer, and an outer shell that can be mass produced to protect any custom inner shell.  The inner shell will consist of two halves that will fit tightly into the two halves of the outer shell.  The outer shell will have a locking mechanism that can be unlocked with one hand.

  5. Information Collected • When we first started to research removable casts, we discovered that there were already some being used such as the ones at www.exosmedical.com.  Since we were thinking about using additive technology, the exos models were produced differently and therefore was of no consequence to our design.  There are a few additive designs that have been created recently but none that is being produced by a company.  Here are a couple examples of what others have come up with:  http://makezine.com/2013/06/20/how-to-make-a-customized-and-removable-wrist-cast/ • http://www.nydailynews.com/news/world/3-d-printed-cast-future-article-1.1398383 • We read various websites on additive technology and found that the use of it in the medical field is increasing rapidly.   It is likely that in the near future, 3D scanning and printing will be a common practice at hospitals.  Therefore, a cast designed with the technology would have a short lead time since the printer will reside at the hospital.

  6. Development of Alternative Solutions • A separate outer shell made out of polycarbonate or a similar material will keep the bone safe while maintaining a solution that is lightweight.  An added benefit of the outer shell is that it gives a spot to put a fastening mechanism without worrying about altering the structure of the inner shell.  

  7. Selection of Best Solution • We decided to opt for a design that utilizes a latching mechanism to lock the outer shell into place because it gives a low profile that can be flush with the contour of the outer shell design.  With two on each side and the shells fitted with some dowel pins and loose fitting dowel holes, the outer shell will be able to be taken off and put back on easily with one hand.  Being able to take it off and put it back on will enable the wearer to cleanse the area and the cast itself to prevent smells and to alleviate the itching that occurs from wearing a cast for weeks.

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