Halcyon cast: A modular orthopedic cast for self-managed, empathetic healing

Orthopedic casts, despite advancements from traditional plaster to contemporary 3D-printed materials, have remained fundamentally unchanged, static devices solely intended for immobilization. This stagnation disregards compelling medical research indicating that controlled, progressive mobility combined with patient empowerment significantly accelerates healing and enhances overall recovery. The Halcyon Orthopedic Cast addresses this critical gap, transforming the orthopedic cast from a passive immobilizer into an active, user-centric recovery device. In alignment with global shifts toward decentralized, patient-centered healthcare, Halcyon actively involves users in managing their own rehabilitation, fostering autonomy and reducing dependence on frequent clinical interventions. Halcyon's design integrates a dual-layer system featuring a robust yet lightweight PET-G outer shell for structural stability, and a soft, adaptive TPU inner layer that intuitively accommodates swelling through gentle compression. A modified T-slot sliding mechanism secured with user-friendly Velcro allows for quick, intuitive adjustments by the user, significantly enhancing usability and comfort. Progressive mobility modules incorporated into the design systematically encourage incremental movement aligned with the body's natural healing processes, potentially reducing recovery time and preventing muscle deterioration. The strategic choice of materials, PET-G and TPU, combined with additive manufacturing (3D printing), ensures an optimal balance between strength and flexibility, breathability, comfort, and adaptability. Iterative prototyping and testing revealed Halcyon's clear advantage in dynamically accommodating swelling and progressively enabling user mobility, effectively translating medical research into tangible, practical innovation. Although formal clinical validation remains an opportunity for future research, the project's initial findings underscore the pivotal role industrial designers can play in bridging healthcare research and user-centered product innovation. Broadly, Halcyon exemplifies a necessary evolution in design of medical devices, emphasizing intentional human-centered interventions within a field traditionally dominated by clinical functionality alone. By thoughtfully merging empathetic aesthetics and practical innovation, Halcyon not only enhances physical recovery but profoundly addresses emotional and psychological challenges users face during rehabilitation. This thesis advocates for a multidisciplinary approach, positioning industrial designers as essential contributors capable of significantly improving patient experiences and shaping more compassionate healthcare solutions.

Name thesis:degree_name

M.F.A.

Level thesis:degree_level

Thesis

Discipline thesis:degree_discipline

Art and Design

Grantor

University of Illinois Urbana-Champaign

Year dc:date

2025

Author dc:creator

• Waichal, Harsh Milind

Contributors dc:contributor

• Sethi, Suresh
• Amos, Jenny

• Human-centered Design
• Medical Device Innovation
• Orthopedic Cast
• User Empowerment
• 3d Printing
• Adaptive Design
• Progressive Mobility
• Industrial Design For Healthcare

Statement dc:rights

• Copyright 2025 Harsh Waichal

Language dc:language

en, eng

Handle dc:identifier

https://hdl.handle.net/2142/129643

OAI record oai:identifier

https://www.ideals.illinois.edu/oai-pmh?verb=GetRecord&metadataPrefix=etdms&identifier=oai%3Awww.ideals.illinois.edu%3A2142%2F129643