Cast-It
Transforming how we protect and heal injuries.
Problem Statement
Current post-orthopedic care relies on reactive symptoms rather than proactive data, often resulting in complications that are only identified once irreversible damage has occurred.
Solution
A smart medical multisensor cast that identifies complications and alerts the user before problems become severe.
Company Mission Statement
At Cast-It, we protect casted limbs by making hidden pressure and temperature fluctuations visible before they cause complications.
Medical Research
We began our process by interviewing Dr. Noah Chinitz, a pediatric orthopedic surgeon specializing in foot and ankle pathologies. Our goal was to understand the day-to-day challenges faced by surgeons and patients during orthopedic recovery. By consulting with a clinical expert early in the ideation phase, we were able to transition from a broad concept of "smart casting" to a targeted medical tool designed to monitor the healing process. After speaking with Dr. Chinitz, here is what we learned.
Pressure and Temperature Tracking
During our initial brainstorming, we explored various methods for monitoring cast health, including moisture, pulse oximetry, temperature, and pressure. However, based on Dr. Chinitz’s guidance, we decided on a dual-sensor approach focusing on pressure and temperature because they are the most reliable physiological markers for the two most dangerous post-operative complications: Compartment Syndrome and Infection. Excessive pressure within the rigid environment of a cast indicates internal swelling that can restrict blood flow and cause permanent tissue damage in as little as six hours. Meanwhile, temperature spikes serve as an early warning system, often detecting the body’s inflammatory response to infection or Deep Vein Thrombosis (DVT) up to 48 hours before physical symptoms like redness or discharge appear. By focusing on these two variables, we transitioned from a subjective "pain-based" monitoring system to an objective, data-driven safety system.
Optimal Sensor Placement
A major challenge was determining where to place the pressure sensors so they would provide high-accuracy data without compromising the patient's skin integrity or comfort. Following the advice of Dr. Chinitz, we avoided placing sensors directly over bony prominences (such as the malleolus/ankle bone), as these areas are prone to false pressure spikes and skin irritation. Instead, we positioned the pressure sensors in the distal and mid-foot regions, where they can most accurately measure the "squeeze" caused by swelling against the cast wall. Through iterative testing, we moved the hardware from the top of the limb to a protective foam housing under the foot. This placement not only protected the electronics and improved signal consistency but also utilized the natural weight of the limb to ensure constant sensor contact without causing discomfort to the patient.
Data Frequency and Thresholds
Beyond collecting data, we had to determine the appropriate frequency and "trigger points" for medical intervention. Through our research and consultation, we established two key protocols:
The 5 Minute Sync: We chose a frequency rate of 5 minutes for our dashboard. While clinical changes in a cast usually happen over hours, the high-frequency sync is essential for "system validation" -- ensuring the patient knows the device is active, and the Bluetooth connection is stable, thereby reducing user anxiety and the need for technical assistance
Defining the "Danger Zone: A single high reading doesn't always mean an emergency. Our software logic is designed to look for sustained trends. For example, a temperature spike is only flagged as a potential infection if it remains elevated above the patient’s baseline for a specific duration. This prevents false alarms caused by temporary external factors, such as the patient sitting near a heater or exercising.
Market Research and Analysis
Prototype
Engineering Schematics
Demo Video
Prototype Iteration and Google Drive
CLICK HERE to take a deeper dive into our year-long evolution, including early sketches, pitch decks, and technical demos in our Google Drive.
User Testing
Because we are currently in the prototype phase, we are not yet legally authorized to conduct clinical trials. Instead, we performed a simulated study on a cohort of 20 students to evaluate the ergonomics, comfort, and software-hardware interaction of the Cast-it system. This allowed us to gather critical "user-experience" data before moving toward medical-grade testing.
Based on user testing, we made one key change to our prototype. We changed the housing from a 3D shell to a foam container located below the foot area. We went back and tested this change on 5 people, who all said that they experienced no discomfort and couldn't even tell that the technology was under their feet.
We asked our 20 participants to rate the system across three core categories: wearability, usability, and the app user interface. Here is the breakdown of our findings:
Wearability: 9.2/10
Most users forgot the device was attached within 10 minutes of wear. They experienced no discomfort aside from the initial transition into the cast.
Durability: 6.1/10
While the sensors performed well and held up under movement, the 3D-printed casing showed signs of stress.
App User Interface: 8.5/10
The clickless Bluetooth sync was described as "seamless" and "fast." Seeing the data update in real time provided students with instant peace of mind that the system was working.
Testimonials
Sheila, 76 - Patient
"After my surgery, my biggest fear was that I wouldn't know if something was wrong until it was too late. I live alone, and being able to see that my pressure levels were normal gave me the confidence to sleep through the night without worrying about swelling. Cast-It turns what would be a scary recovery into a manageable one."
Dr. Noah Chinitz - Orthopedic Surgeon
"The weeks between cast application and removal has always been a clinical blind spot. With this system, I’m will no longer have to rely on a patient’s subjective description of pain over the phone. I can look at objective data trends and see an infection brewing via temperature spikes days before the patient even feels ill. It’s a complete shift from reactive to proactive medicine."
David, 45 - Caregiver
"Managing a loved one’s recovery is exhausting when you’re constantly checking their fingers and toes for color or temperature changes. This technology takes the guesswork out of caregiving. For the hospital system, it means fewer 'precautionary' ER visits that clog up our waiting rooms. We can prioritize the patients who actually show physiological distress, making our entire facility more efficient."
Competitor Advantage
Cast-It is the only product on the market that is cast integrable, detects pressure and temperature, alerts the user in real time through an app, and costs less than $100.
Revenue Model
