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FIXECURE is an all-new type of cast that aims to be lighter, more breathable, more durable, and quicker-to-set than the old fashioned way.



If you‘ve ever broken a bone, you probably remember how uncomfortable it was to wear a heavy, itchy and unhygienic cast. It‘s almost as bad as the broken bone itself! Fixecure is a brand-new type of cast that is designed to be lighter, more breathable, durable and user-friendly than a common plaster cast

First and foremost, its personalized structure stabilizes the wrist, which is a crucial step in bone healing. Unlike casts, which restrict air circulation, the Fixecure‘s open shape and airy sleeve keep the body dry and allow air to circulate over the skin. Last but not least, the Fixecure‘s customized shape fits the arm precisely. Each Fixecure is individual and based on a scan of the affected area of the body. This process is automated, so a coded model can be generated directly from the scan, ready for 3D printing in no time.

Also, the cast supports the user‘s healing process and adapts to personal needs over time. Therefore, the cover shell can be easily removed through our locking mechanism when the initial protection and immobilization is no longer needed. In addition, the user can choose between elastic and fixed straps, or change them when desired. Depending on what is more comfortable or needed to provide maximum support.

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  • First, the sleeve is put on, which replaces a bandage. This is much easier to put on due to its elastic property and well ventilated on the skin. The sleeve would be available in different sizes.

  • The main support is formed by the base shell. Its structure stabilizes the wrist which is a crucially important step in bone-mending. It will be individualized and therefore perfectly fits the palm and the entire forearm.

  • The cover shell is particularly important for immobilization and brings, through our chosen shape, the highest protection in our cast.

  • For fastening we have chosen Velcro. Velcro is very easy to handle and understand. In addition, it is very decent and brings the advantage that it can be easily adjusted to fit exactly. It was also important that the fastener tightens both shells evenly on both sides, which is made possible by this type of fastener.

  • In addition, our fastener allows the cover shell to be removed. When the healing process is advanced, a strong immobilization is no longer necessary to the same extent. Therefore, the support of the base shell is sufficient to support the forearm. It was important to us that our product supports the healing of the user and adapts to the needs over time.




We started the project with extensive research into various possibilities and scenarios. Through user journeys we tightened our project area to be able to decide on a possible scenario. For our project we wanted to use the forearm as the processing area. For this we had to deal with some questions.

Which phases are there in the healing process and where do we want to approach them?

Which products are used in case of forearm fractures and why?

What characteristics do we need to incorporate into our product and what possibilities are there for improvement?




In the beginning we built some models out of cardboard to get a better understanding of the shape and in which way an arm can be immobilized and protected.

We have also experimented with possible closures. These had to be adjustable on the one hand and removable on the other.




Testing different ways to wrap the forearm and stabilize it in different ways was important, to get a better understanding of its shape and composition.




Next, we scanned our arms to take advantage of the free modeling capabilities in the digital. This was also the first step for us to make our cast customizable. We also milled out our arms to test our shapes directly on them.







We 3D printed some of our prototypes and tested different ideas and shapes. Through this process we understood where to put the connection and how to generate the maximum protection. We also came up with our concept of dividing the cast into two shells that are connected by a fastener.





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Based on the 3D scan of our arms, we created an offset of the forearm and used it as the basis for our prototypes. We divided the model into 2 opposing surfaces (base shell, cover shell) and worked out a sophisticated shape.

In doing so, we were able to develop a working routine in which we could create a model for each possible arm individually, step by step.




For our product, we decided on a simple, modern design that does not directly remind of a hospital. It should integrate into everyday life and also offer a new approach from an aesthetic point of view. However, the most important aspect for us was to make Fixecure significantly more functional and comfortable than existing products. Nevertheless, we have integrated all the necessary features of these products, which are essential for a healthy healing process.




  • The sleeve is made of a medical ventilating, eco-friendly fabric. It lies comfortably on the skin and is very adaptable due to its elasticity. It would be available in several sizes.

  • Two shells are produced with an SLS 3D printer. This makes them significantly lighter and more stable than plaster. It is also very easy to recycle the material into raw powder.

  • The fastening straps are available both elastic and fixed, depending on the choice of the user. They have a grip to assist the use. Both straps are reusable.




If you accidentally get injured and break your arm, you will go to the hospital or clinic to get proper treatment and scan your injured arm. By applying the scanned arm file to the coded model, just like grasshopper, it will be converted easily into a cast shell , which perfectly fits your scanned arm.

After then print the shell with an sls printer and assemble the fastener and sleeve together.

Now get you fixecure and enjoy a much more convenient and hygienic life than plaster cast.

After a certain period of time, if the bones are fixed to some extent,

You are also able to use only the base shell and take off the cover shell after consultation with a doctor.

After the arm is completely healed, you can return the fixecure and get your deposit back. Most of the materials are made of recyclable materials, and able to use multiple times.

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Art des Projekts

Studienarbeit im zweiten Studienabschnitt


foto: Prof. Nils Krüger foto: Jörg Hugo foto: Martin Schatz foto: Adrian Haase foto: Anna Runge foto: Julian Goretzky foto: Sebastian Summa

Zugehöriger Workspace

hands on - care


Sommersemester 2023