Revolutionary 3D-Printed Cast in Singapore: Comfortable, Waterproof, and Cost-Effective Healing

Breaking an arm or wrist is painful enough, but the discomfort of a traditional plaster or fiberglass cast—hot, itchy, and impossible to get wet—adds unnecessary misery. In Singapore, patients at select hospitals and clinics now have a modern alternative: an open, 3D-printed cast that is fully waterproof, more comfortable, and designed for easier application.

Developed by Castomize, a Singapore-based startup, the cast is reshaping the healing process. Unlike conventional casts, which require 10 steps and multiple materials, the 3D-printed version simplifies the procedure. A medical team heats the cast to make it soft and flexible, wraps it around the injured limb, and secures it with built-in buckles. As it cools, the cast hardens in place, providing a precise fit.

“Clinicians need to avoid wrapping casts too tight or too loose, where both scenarios would cause healing complications such as pressure injuries,” explains Abel Teo, CEO of Castomize. Traditional casts often require adjustments or replacements if they become too loose over time, forcing patients to return to the clinic—sometimes at the clinic’s expense. With the 3D-printed cast, clinicians can easily remove, reheat, and reuse it, eliminating the need for costly recasting.

Cost Efficiency and Sustainability

The 3D-printed cast is approximately 30% to 50% more expensive to produce than a traditional fiberglass cast. However, the long-term savings are significant. In a trial conducted by a Singapore hospital, the new cast led to an average 25% reduction in overall costs, thanks to fewer clinic visits and reduced material waste.

Looking ahead, Castomize plans to introduce a sanitization process, enabling the casts to be reused multiple times for different patients. The company refers to its technology as “4D printing,” as the final product incorporates the fourth dimension of time, allowing it to change shape after printing.

Standardized Design vs. Customization

Unlike some competitors, such as ActivArmor, which uses 3D scanning for a fully customized fit, Castomize’s cast comes in standard sizes for both adults and children. This approach reduces production time and costs while maintaining effectiveness. The standardized design does not compromise comfort or functionality, according to the company.

From Student Project to Medical Breakthrough

The concept for the 3D-printed cast originated as a student project at the Singapore University of Technology and Design in 2017. One of the cofounders, Johannes Sunarko, revisited the idea for his master’s thesis in 2021. He later partnered with Eleora Teo and Abel Teo (no relation) to launch Castomize and bring the product to market.

After clinical trials confirmed its effectiveness as a replacement for traditional wrist casts, the product received medical device approval in Singapore and debuted commercially last year. It has since gained regulatory approval for sale in Australia, South Korea, and Taiwan.

Castomize is currently pursuing FDA approval in the United States and the CE mark for Europe, which would further expand its global reach. The company has also expanded its product line to include models for the ankle and elbow, each requiring unique design considerations.

“We needed to work closely with clinician experts in ankle fractures and casting, along with researching and experimenting with different geometries and material combinations,” says Abel Teo. This collaborative approach ensures the casts meet the specific needs of each body part.