a new generation of orthopedic casts
Castomize is developing a new generation orthopedic casts in Singapore, using ‘4D-printingTo make limb immobilization lighter, cleaner and easier to adjust. The company’s cast system moves away from the dense, coiled structure of fiberglass and toward a prefabricated mesh shell that softens with heat, molds directly to the patient’s extremity, and hardens again as it cools.
Recently appeared as part of PROTOTYPE ISLAND during Milan Design Week 2026the product began as a research project at the Singapore University of Technology and Design before emerging as a medical technology company in 2022. Its principle is straightforward, stating that a cast should hold the body securely while allowing the skin to breathe, water to pass through, and adjustments to be made without cutting through layers of rigid material.
image via Castomize
a plaster formed through heat
Castomize’s main product is a remoldable orthopedic cast made from smart thermoplastic materials and a moisture-resistant inner layer. Each piece is pre-produced and then heat-activated in the clinic. Once heated, the fibers become flexible enough for a healthcare professional to mold the cast around the patient’s wrist, forearm, elbow or ankle, depending on the model.
This approach gives the product the “4D-printed” label. The fourth dimension is time: the printed object changes state when exposed to heat, allowing a standardized part to adapt during application. Plaster is heated, placed around the limb, cut into place and allowed to cool to a stable support structure. THE group describes the process as faster and cleaner than conventional casting, requiring no 3D scanning and no casting saw for removal.
image via Castomize
waterproof, breathable and built for clinical use
The most visible difference is the open mesh structure. Instead of covering the limb in continuous layers, the Castomize cast uses a perforated shell that allows air to circulate through the skin. The company positions this breathability as one of the main advantages of the product, especially for patients who experience itching, sweating or irritation under traditional casts.
The cast is also described as completely waterproof, which changes the way patients can wash, shower and move around during treatment. The team even notes that the cast can be used while swimming, although medical guidance for this remains in the hands of healthcare professionals. Casts are single-patient devices, but can be reheated and reshaped for the same patient if swelling or repositioning is required.
standard fittings with a custom fit
A key part of Castomize’s design strategy is that the cast does not depend on a separately scanned and printed object for each patient. Instead, the company uses pre-made sizes that are customized during fitting. This gives the device a different position in the growing field of 3D printed medical products: it keeps the clinical workflow closer to existing molding, while still using advanced manufacturing to change the object itself.
For clinics, this could mean a simpler adoption path. The cast can be placed, heated, applied and set without waiting for a custom print. For patients, the experience is shaped by the physical properties of the final object: lower weight, visible ventilation, waterproof use and easier removal.
project information:
company: I customize
