"Bracesys sidesteps all these limitations with an adjustable framework of segmented units, articulating connectors, and tension dials. The entire system weighs just 150 grams and folds flat into an envelope, yet provides rigid support comparable to traditional casts. More remarkably, clinicians can customize it to each patient's anatomy in real time, adjusting the fit as swelling decreases and healing progresses."
"Kevlar cables run through the framework and get tightened via integrated dials, borrowing directly from sailing rigging where distributed tension points create precise control. Yacht rigging achieves massive structural loads through this exact principle. Osteoid just applied it to wrist immobilization. The framework comes from SLS and MJF 3D printing with medical-grade Nylon 12, reinforced at stress points with CNC-machined aluminum and stainless steel."
Bracesys adapts precision mechanical principles from watchmaking and sailing rigging to wrist fracture immobilization. The system uses an adjustable framework of segmented units, articulating connectors, Kevlar cables, and integrated tension dials to deliver rigid support while remaining lightweight. The complete device weighs 150 grams, folds flat into an envelope, and allows clinicians to adjust fit in real time as swelling decreases and healing progresses. A hybrid manufacturing strategy combines SLS and MJF 3D printing in medical-grade Nylon 12 with CNC-machined aluminum and stainless steel reinforcements at stress points to achieve organic geometries and load-bearing strength. Over 600 anonymized CT scans informed AI-driven segmentation, implicit skinning, and PCA-based sizing.
Read at Yanko Design - Modern Industrial Design News
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