---
title: "Castomize’s heat-molded 3D printed orthopedic cast has reduced costs by up to 25%"
url: https://www.voxelmatters.com/castomizes-heat-molded-3d-printed-orthopedic-cast-has-reduced-costs-by-up-to-25/
date: 2026-05-10
modified: 2026-05-09
lang: en
author: "Joseph Caron-Dawe"
description: "A Singapore-based startup, Castomize, has developed a 3D printed open cast for wrist, arm and ankle fractures that is breathable, lightweight, and fully waterproof, and which helps avoid common side..."
categories:
  - "Medical AM"
  - "Personalized Medicine"
tags:
  - "insights"
image: https://www.voxelmatters.com/wp-content/uploads/2026/05/Castomize-cast-02-640x400.jpg
word_count: 353
---

# Castomize’s heat-molded 3D printed orthopedic cast has reduced costs by up to 25%

A Singapore-based startup, Castomize, has developed a [3D printed open cast for wrist, arm and ankle fractures](https://www.voxelmatters.com/activarmor-and-fusion3-offer-in-clinic-custom-3d-printed-cast-fabrication/) that is breathable, lightweight, and fully waterproof, and which helps avoid common side effects of traditional casts such as pressure injuries.

The product originated as a student project at the [Singapore University of Technology and Design](https://www.voxelmatters.com/singapores-lta-to-build-countrys-first-3d-printed-concrete-pedestrian-bridge/) in 2017, and co-founder Johannes Sunarko returned to it as a master's thesis in 2021 before joining forces with fellow former students Eleora Teo and Abel Teo to bring it to market. 

Following clinical trials that confirmed its effectiveness as a replacement for a traditional wrist cast, the device received medical approval in Singapore and came to market last year. It has since gained clearance in Australia, South Korea, and Taiwan, with applications for US Food and Drug Administration (FDA) approval and the CE (European Conformity) mark currently in process.

[![](https://www.voxelmatters.com/wp-content/uploads/2026/05/Castomize-cast-03-640x400.jpg)](https://www.voxelmatters.com/wp-content/uploads/2026/05/Castomize-cast-03.jpg)

[![Castomize’s heat-molded 3D printed orthopedic cast has reduced costs by up to 25%](https://www.voxelmatters.com/wp-content/uploads/2026/05/Castomize-cast-01-640x400.jpg)](https://www.voxelmatters.com/wp-content/uploads/2026/05/Castomize-cast-01.jpg)

## A different approach to fracture management

The cast is produced on a standard 3D printer, but changes shape after manufacture. Its application involves heating the cast until it becomes pliable, wrapping it around the patient's limb, and securing it with built-in buckles.

As it cools, it conforms and hardens to the individual arm. Unlike other solutions that rely on 3D scanning to produce a custom-fitted device, Castomize offers standard sizes for both adults and children, keeping production time and costs lower.

Conventional casting processes require multiple steps and several materials. “Clinicians need to avoid wrapping casts too tight or too loose, where both scenarios would cause healing complications such as pressure injuries,” said Abel Teo, Chief Executive Officer of Castomize.

If fit issues arise or the cast loosens during recovery, a clinician can remove, reheat, and reapply it rather than starting over with new materials.

## Cost and reusability

The device costs 30% to 50% more to produce than a fiberglass cast, but the reduced recasting requirements can offset that premium at the facility level.

In one Singapore hospital trial, Teo claimed average cost savings of 25%. The company is also developing a sanitization process that would allow individual casts to be reused across multiple patients.