Prefabricated Casting System with Rocker Walker Design

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Solution Overview

Problem

Conventional total contact casting systems are time-consuming, costly, and cause patient discomfort due to length discrepancies and back/hip pain, while also being difficult to apply and remove, leading to underutilization in treating diabetic and neuropathic foot ulcerations.

Innovation Solution

A proprietary, user-friendly casting system with a unique configuration of self-adhesive felt strips and a multi-layer prefabricated support splint that reduces application time, minimizes cast length, and facilitates easier removal, using a rocker walker design to promote normal biomechanics and reduce pressure on the ulceration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional total contact casting systems are used to treat diabetic and neuropathic foot ulcerations, then intimate contact and pressure offloading are achieved, but application time is excessive and patient discomfort increases

Engineering Contradiction:

Improveintimate contact and pressure offloadingVSAvoidapplication time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The casting system incorporates pre-formed components including a pre-shaped cast body with integrated pressure relief channels, pre-positioned padding layers, and pre-assembled structural elements that maintain intimate contact with the limb. These preliminary preparations eliminate time-consuming manual shaping and positioning steps while ensuring consistent pressure distribution and intimate contact.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cast is divided into modular segments including a main body portion, removable components, and separate pressure relief elements. This segmentation allows for rapid assembly by simply connecting pre-fabricated sections rather than applying and shaping a single continuous cast, significantly reducing application time while maintaining the integrity of intimate contact and pressure offloading.

Inventive Principle:

Principle #1Segmentation

2Reliability

If conventional total contact casting systems are used to treat diabetic and neuropathic foot ulcerations, then pressure offloading is achieved, but material cost and complexity increase

Engineering Contradiction:

Improvepressure offloadingVSAvoidcasting system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple functions are merged into single components: the cast body integrates pressure relief channels, structural support, and intimate contact surfaces in one unified structure. Padding layers are pre-attached to specific zones, and pressure distribution features are built-in rather than added separately. This merging reduces the number of separate materials and steps required while maintaining effective pressure offloading.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The casting system is designed as a universal platform that can accommodate various limb shapes, sizes, and ulceration locations through adjustable and adaptable components. The same basic cast design can be configured for different patients and conditions, reducing the need for multiple specialized cast types and associated materials, thereby simplifying the overall system while maintaining pressure offloading effectiveness.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If conventional total contact casting systems are used to treat diabetic and neuropathic foot ulcerations, then wound healing is promoted, but patient mobility and quality of life deteriorate

Engineering Contradiction:

Improvewound healingVSAvoidpatient mobility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The casting system incorporates dynamic elements including articulated joints, flexible segments, and controlled mobility features that allow necessary movements while maintaining therapeutic pressure offloading. The cast can adapt to different positions and activities, enabling patients to maintain mobility and quality of life while the wound heals. removable components allow for periodic assessment and adjustment without complete cast removal.

Inventive Principle:

Principle #15Dynamics

4Reliability

If conventional total contact casting systems are used to treat diabetic and neuropathic foot ulcerations, then pressure distribution is improved, but cast weight and patient discomfort increase

Engineering Contradiction:

Improvepressure distributionVSAvoidcast weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The cast incorporates porous materials that provide structural support and pressure distribution while being lighter than traditional solid cast materials. The porous structure maintains mechanical integrity for effective pressure offloading while reducing overall weight, thereby improving patient comfort and reducing fatigue without compromising the pressure distribution required for wound healing.

Inventive Principle:

Principle #31Porous materials

Data Source

PatentUS9433535B2Modality and system for casting diabetic and neuropathic plantar foot ulcerations and treating defects that limit range of motion

Publication Date: 2016.09.06 CRAGO MICHAEL G

AI summary

A system that is clinically and effically sound, consisting of proprietary components that not only address the needs of the clinician but are universally utilized in a concise protocol covering a wide range of indications and conditions.