FINAL REPORT

EGBI 180 Entrepreneurial Mindset for Biomedical Engineering

TOPIC: 3D PRINTING IN MEDICINE

GROUP 5 Class of 2021

Final REPORT : GROUP 5

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GROUP MEMBERS
1. Ravinun Khamleart 6413353 EGBI
2. Biradaht Lertpanyaroj 6413380 EGBI
3. Gunn Kittichaidamrong 6402001 RAMD
4. Napasorn Chuaychoowong 6305206 SCPL
5. Wongtawan Boonranawichit 6305048 SCPL

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 ABSTRACT
When we think of a cast for a bone fracture, we’d usually imagine the conventional,
white plaster cast used frequently by orthopedists. And for someone who has ever
worn one due to some sort of accident that resulted in a bone fracture, they’d also
think about the discomfort they experienced as well. Every little detail is important to
our user's experience because bone fracture injury can last from a few weeks to a
couple months. We have to be able to maintain good condition of the injured area
throughout the recovery process. So how can we redesign a product which can get rid
of the problems the traditional cast has?

We decided to research 3D-printed casts and test if it had a better impact on users
and if it would be more ideal for mainstream use? One of the popular trends in these
past few years has always been 3D printing. It cost a reasonable price and by using a
3D printer. In the design thinking method, we interviewed people who had worn a
plaster cast before, with their experiences they shared, we came up with solutions and
designed a prototype and calculated how much the expenses were before testing it to
find out whether a 3D printed cast would be better and worth the price. We
conducted another survey after finishing the cast design for some feedback on our
product’s functionality whether it will satisfy the needs of those individuals or not.

The results we collected showed 85% of the respondents found the product appealing
with useful features and agreed that the price was worth paying for. From this report,
a 3D printed cast can be a possible option for patients that desire a comfortable,
affordable and effective treatment.

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Table of Contents
Group Members 2

Abstract 3
Project Background 5
Research Methods & Tools 5
Customer – Problem Fit 8
Persona 8
Interview Methods & Results 8
Customers’ Insight Summaries 9
Solutions 10
Existing Solutions in the Market 10
Proposed Solution & Prototype
Prototype Validation & Testing 11
Conclusion 13
Reference 14

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PROJECT BACKGROUND 
Background of the topic, the importance, root of problems, etc.

         Casts have been a tool for orthopedics since ancient times and still improve until
the present. But it is still far from being flawless. One of the main problems that
patients who wear casts have faced is that a cast is a solid object aimed at making
limbs stay still, so being uncomfortable is somewhat unavoidable. 

       Researchers, doctors, and innovators then came up with a brilliant idea that
makes up for the flaws of the traditional casts, a 3D-printed one. It is far more pleasant
and light compared to the old one while serving the same purpose of keeping the
injured limbs fixed. But there are still some improvable aspects such as being
adjustable or attaching some other features to it.

       For this reason, we have come up with a solution of our own by utilizing the
‘design thinking’ method. This improved version of the 3D-printed cast can cover most
problems so the patients would have better experiences while wearing it.

Research Methods & Tools

We used these three main methods to conduct this project.
1.) We attended a lecture engaged in discussion sessions with our mentor,
Assoc.Prof.Dr. Paphon Sa-Ngasoongsong, who is an orthopedist at Ramathibodi
Hospital and also is the leading person for planning to introduce 3D printing from
overseas as a means to design a better cast in comparison to the conventional one. To
sum up, what we had learned from those sessions, we gained basic information about
casts, 3D-printed technology, and related topics.

2.) After we obtained that basic knowledge, we dug further into the internet, to
the realm of research papers, to get more information about this new technology and
its applications. We used all the information we had gathered to discuss further and
make a prototype through the ‘design thinking’ method.

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 3.) For further research tools, we conducted interviews for qualitative data and
created a survey via google forms to gather quantitative data and feedback about our
prototype from those who used to have an experience with cast, either as patient or an
orthopedic doctor/nurse.

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Related study

1.Chen, Y., Lin, H., Yu, Q., Zhang, X., Wang, D., Shi, L., Huang, W., & Zhong, S. (2020). Application
of 3D-printed orthopedic cast for the treatment of forearm fractures: Finite Element Analysis and
Comparative Clinical Assessment. BioMed Research International, 2020, 1–12.
https://doi.org/10.1155/2020/9569530 

This research is about the basics and mechanical characteristics of a 3D-printed cast wrapped
on the forearms. It also mentions the uses of 3D graphic model technology which assist the
procedures of making 3D-printed casts.

2.P Fitzpatrick, A. (2017). Design of a patient specific, 3D printed arm cast. KnE Engineering, 2(2),
135. https://doi.org/10.18502/keg.v2i2.607 

This research focuses solely on the manufacturing technique of 3D printing objects. This study
also evaluates the feasibility of designing the patient specific cast to match his/her anatomy. It also
mentions the use of ‘right’ biocompatible material for 3D-printed casts.

3.Chen, Y.-J., Lin, H., Zhang, X., Huang, W., Shi, L., & Wang, D. (2017). Application of 3D–printed
and patient-specific cast for the treatment of distal radius fractures: Initial experience. 3D Printing in
Medicine, 3(1). https://doi.org/10.1186/s41205-017-0019-y 

This study shows that 3d-printing technology can be applied to the medical field by comparing
3D-printed casts to their traditional counterparts. The result shows that the customizable ability of the
3D-printed casts make it superior in terms of flexibility and comfortability.  

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CUSTOMER – PROBLEM FIT
Persona

Figure 3. Persona created using the information from interviews

Mr. Jay, an 18 years old freshman from the faculty of science living in Bangkok. He loves to play
sports like biking, running, basketball, and cheerleading. He has been wearing a traditional cast on
his arm due to an accident while he was playing sports. The cast has been giving Jay problems such
as itchiness, heavy weight, unadjustable, and difficulties from taking showers because the cast could
not get wet. In fact, he wishes one day there must be a cast  that reduces the healing process,
preserve as much mobility as possible, cause less skin irritation, and importantly have a better quality
of life while wearing a cast.

Interview Methods & Results

1.) Empathy interview : the first round interview that we talked to 20 people that had been
experienced with wearing casts. In order to identify the suitable problems to solve, we need to
understand them from a behavioral standpoint. Empathy interviews will assist us in better
understanding users' demands as we have a better grasp of the people we are designing for. We use
3 types of interviews including virtual, telephone, and in-person interviews. Our study group were
patients who used to have an experience with a cast from Thailand, United States, and England. We
also discussed with orthopedic doctors and nurses. According to the interviews, 75 % of people that
had been experienced with wearing traditional casts were men, 64% of them were in the age 19, and
85% were undergraduate students. As result based on using empathy map-the four quadrants that
describe what the user did, thought, and felt-found that 80% feels uncomfortable with wearing cast
due to itchiness and restrictive movement, 60% said the tradition has heavy weight, 55% has
difficulties in showering, and 35% said the cast has unpleasant smell. 

2.) Product testing interview : the final round interview where we interview the same group of

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people as the first interview. At this time we ask about our solution, whether it could solve the problem
or not, find out if they like it, and what values do they see in the product. By compiling this survey, we
hope to build customer-centered products and reduce the risk of failure. It's a good method for testing
our design concept, and if users disagree, we'll know how to improve before releasing the product. In
this time we created a survey via google forms to gather quantitative data and feedback about our
prototype. As a result, 55% of people have no concerns about the adjustability of the cast and found
the vibrational therapy useful, and 65% of them said palm-mesh is a necessary feature for the cast.
Therefore, the product that most appeals to the users are every aspect (40%) including 30% of ability
to adjust, 25% of vibrational treatment, and 5% of palm-mesh.

Customers’ Insight Summaries 

After doing the two rounds of interviews; empathy and product testing, we found that most of the
patients were men who were undergraduate students. Overall, people feel uncomfortable with
wearing casts due to itchiness, restrictive movement, heavy weight, difficulties in showering, and
unpleasant smell.
Then we ideate with our team and mentor to find out the best solution for users, create the prototype,
and gather feedback about our prototype from those who used to have an experience with
cast. Many of them are unconcerned with the cast's adjustability and find the vibrational
therapy to be beneficial, and some of them believe palm-mesh is an essential element of the
cast. As a result, every component of the product, including the ability to adjust, vibrational treatment,
and palm-mesh application, appeals to users the most.

Figure 4. Summary of the main problems Figure 5. Empathy maps from 20 interviewee

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 SOLUTIONS
Existing Solutions in the Market

The current solution in the market is from XKELET company which also offers 3D
printed casts as well, but the cast is not adjustable. The price range is substantially
higher than our model proposal.

Proposed Solution & Prototype

We chose three main solutions and started designing our low-resolution prototype by
sketching out the dimensions and noting key features that pointed to the solutions.

Figure 6. Adjustability using fixation straps  Figure 7. Vibrational Treatment

Figure 8. Porous material and mash applied to the palm area

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Final REPORT : GROUP 5
Prototype Validation & Testing

Our method of testing was to create a survey via google form. Within it, we showed
pictures of our proposed prototype with concise descriptions of its 3 main features: 1)
the product’s ability to adjust, 2) vibrational therapy that can be applied for a more rapid
healing process, and 3) mesh material applied to the palm area of the hand to reduce
sweat build-up (a common cause of skin irritation). After this brief run-through, we
provided questions about each feature to find out if they were trustworthy, useful, what
was the most appealing, and whether our product would be worth its value.
The quantitative data results of our 20 respondents are as follows: 

Figure 9. Gender, age and current education of the respondents

Figure 10. The respondents’ views on each feature of the prototype

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Final REPORT : GROUP 5
We categorize our respondents based on their age group, gender, and occupation. The
majority portion of our target group are male with an average age of under 20. This
group of people represents the most active period of life and the most likely to receive a
fracture injury.

Most of the respondents find all 3 functions interesting and necessary for the product
design. The satisfaction of the characteristics provided is very positively responded. We
can expect these individuals to be buying one of our products if it happens to be
produced.

Figure 11. Views on the features (individual evaluation)

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Final REPORT : GROUP 5
CONCLUSION
From the feedback we received from the survey, we’ve concluded that this project possessed the potential to advance
into a bigger scale. Firstly identifying the current problems we have with the traditional cast, conduct a survey, research
along with consulting with our mentor. After a thorough consideration and process, we finally came up with a product
idea. Our product offers an effective and efficient way of treating fractured body parts along with a reasonable price. An
adjustable waterproof cast which can be implemented with vibrational treatment. Our product is also made with a
biocompatible and biodegradable material so we can exclude the environmental concerns. We strongly believe that our
product will definitely assist our society to move forward in more advanced and efficient treatment methods.

2020 2021 2022

Service ฿320,000 ฿360,000 ฿400,000

Materials ฿720,000 ฿810,000 ฿900,000
Design
฿600,000 ฿675,000 ฿750,000
& Engineering Fee

Printing ฿200,000 ฿225,000 ฿250,000

Total ฿1,840,000 ฿2,070,000 ฿2,300,000

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Final REPORT : GROUP 5
REFERENCE
Behance. (n.d.). Custom Orthopaedic Arm Cast Design. Retrieved October 29, 2021,
from      https://www.behance.net/gallery/77372115/Custom-Orthopaedic-Arm-Cast-
design

Application of 3D–printed and patient-specific cast (n.d.). Retrieved October 28, 2021,
from https://www.researchgate.net/publication/320969393_Application_of_3D-
printed_and_patientspecific_cast_for_the_treatment_of_distal_radius_fractures_initial_e
x

Chen, Y., Lin, H., Yu, Q., Zhang, X., Wang, D., Shi, L., Huang, W., & Zhong, S. (2020).
Application of 3D-printed orthopedic cast for the treatment of forearm fractures: Finite
Element Analysis and Comparative Clinical Assessment. BioMed Research
International, 2020, 1–12. https://doi.org/10.1155/2020/9569530

Buhr, S. (2014, May 29). A 3D printed cast that can heal your bones 40-80% faster.
Retrieved November 22, 2021, from https://techcrunch.com/2014/05/29/a-3d-printed-
cast-that-can-heal-your-bones-40-80-faster/

Chen, Y.-J., Lin, H., Zhang, X., Huang, W., Shi, L., & Wang, D. (2017). Application of
3D–printed and patient-specific cast for the treatment of distal radius fractures: Initial
experience. 3D Printing in Medicine, 3(1). https://doi.org/10.1186/s41205-017-0019-y

P Fitzpatrick, A. (2017). Design of a patient specific, 3D printed arm cast. KnE

Engineering, 2(2), 135. https://doi.org/10.18502/keg.v2i2.607

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Final REPORT : GROUP 5