Abstract

With society progressing through the beginning of the Industry 4.0 revolution, the possibilities that have been created by modern manufacturing techniques and the implementation of the internet of things have allowed for the pipe dreams of previous centuries to become old technology to the youth of today. There has also been a large shift in society’s view of the environment and their impact on it. As a result, many industries have researched the capabilities of modern technologies and adapted them to their field of expertise while taking their impact on the environment into consideration. The field of orthopaedics in the medical industry has adapted to these new capabilities; however, the technique of orthopaedic casting and immobilisation has seen little innovation during this revolution. Using peer-reviewed research and personal interviews with healthcare professionals, the research into this problem sought to apply this knowledge to a product design solution. Experimentation, research, and analysis of prototypes and product solutions within the orthopaedic field helped inform the development of this product design, with the aim of providing an environmentally responsible solution that supports the patient’s long term health goals. This solution also acts as a case study for other areas of the medical industry, aiming to show how the application of environmentally responsible products can be as effective as current products.

Design Intent

Personal injury is a major component of Australia’s health network, with injuries composing 30% of all hospital presentations in the 2017-2018 financial year. This 30% comprises over 273,000 presentations consisting of at least one fracture, with 69,000 of those being fractures of the hand and wrist. Since immobilisation is key to the successful healing of a fracture, orthopaedic casts and other immobilisation devices are used to protect the fractured limb and to reduce the likelihood of further injury.  

The Re:Cast project aims to replace the traditional orthopaedic casting materials and forms to provide an environmentally responsible alternative that does not compromise a patient’s healthcare. By exploiting the capabilities of 3D printing, this solution can also provide healthcare in remote environments where medical supplies are scarce. Whilst most cast and immobilisation products are destroyed after use, the use of PLA allows for the cast to be recycled and used to create another cast, to reduce the environmental impact that the cast has. 

Based around the problem of over 69,000 hand and wrist fractures in the 2017-2018 period, the cast emulates both a Short Arm cast and a Thumb Spica cast, in order to provide flexibility in healing various fractures. Combining this functionality with the simple assembly procedure allows for training doctors to provide a similar level of care to that provided by an experienced doctor. While all these features allow for an appropriate level of care, they do also provide more comfort than the traditional orthopaedic casting and immobilisation products. The overall open nature of the cast that is provided by the simple assembly, and the waterproof properties of the PLA material, create a level of comfort that is difficult to achieve by conventional methods.

Bio

Sam Power is an enthusiastic product designer with a desire to learn and attack any problem thrown at him. This, combined with experience in plastics manufacturing, provides him with the ability to develop designs and bring them to life. Sam has a love for materials and aesthetically pleasing products that are also functional. This drive for functional products is derived from his experience with multiple personal injuries and witnessing the struggles of others as they went about their daily lives. Whilst this is a major component of his inspiration, his passion for mountain biking and the outdoors is a driving force behind his desire to learn and develop a greater understanding of functional designs.

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