WO2022162703A1

WO2022162703A1 - A segmented all-fit adjustable fracture cast for treating bone fractures

Info

Publication number: WO2022162703A1
Application number: PCT/IN2022/050082
Authority: WO
Inventors: Muthukumaraswamy DHARMALINGAM PONNUSWAMY KATHIRESAN; Naveen RABAKAVI; Swetha TARACHANDRA; Srilekha MUTHUKUMARASWAMY
Original assignee: Tattvavai
Priority date: 2021-02-01
Filing date: 2022-01-31
Publication date: 2022-08-04

Abstract

The embodiments herein provide a segmented all-fit adjustable fracture cast (100) for treating bone fractures, comprising a rail mechanism to carry an assemblage of one or more sliding rail holders (6), wherein each of the one or more sliding rail holders (6) configured to carry a pair of mid rails (2) on a turret (3) mechanism mounted on the each of the one or more sliding rail holders (6); an adjustable stub (13) to secure a fractured portion of a hand; one or more stub screws (12) to adjust a stub (13) from time to time based on a swelling of the fractured portion of hand; an adjustable top hand segment casts (8, 10) coupled with the at least one pair of main rails (1) (5); and an adjustable bottom hand segment casts (9, 11) coupled with the at least one pair of main rails (1) (5).

Description

A SEGMENTED ALL-FIT ADJUSTABLE FRACTURE CAST FOR TREATING BONE FRACTURES

CROSS REFERENCE TO RELATED APPLICATION

This application is based on and derives the benefit of Indian Provisional Application 202141004280, the contents of which are incorporated herein by reference.

TECHNICAL FIELD

[001] The present invention relates to orthopedic methods or devices for non-surgical treatment of bones or joints, and more particularly, related to a segmented all-fit adjustable fracture cast for treating bone fractures, tendons, ligaments, and muscle spasms to secure (by immobilizing) the fractured area appropriately.

BACKGROUND OF INVENTION

[002] An orthopedic cast, also known as a body cast, plaster cast, or surgical cast, is a shell made of plaster or fiberglass that encases a limb to stabilize and retain anatomical features, most commonly a fractured bone, in place by immobilizing until healing is confirmed.

[003] Generally, plaster bandages are made out of cotton bandages that have been blended with plaster-of-paris, which hardens after being wet, and the skin beneath the plaster becomes dry and scaly owing to the nature of the dressing, since the discarded outer skin cell is not washed or brushed off. Another disadvantage of plaster casts is their high weight, which restricts movement. Some of other disadvantages are listed below in Table- 1.

[004] In a conventional technique, a bandage cast made of synthetic, or fiberglass material is used to cure a fracture. The bandage made of synthetic/fiberglass material is lighter and dries significantly faster than plastic bandages. The fiberglass bandages, on the other hand, are more difficult to apply and may irritate the skin. Therefore, they must be replaced frequently to avoid skin maceration. Further, some of the other constraints are listed below in Table- 1. [005] In yet another conventional mechanism, a 3D-printed cast for fractured bones replaces the bulky, irritating, and smelly plaster or fiberglass casts. Lightweight, recyclable, and washable, the 3D-printed cast is ideal for outdoor use. However, obtaining a 3D cast takes longer than 5 hours and necessitates the purchase of a 3D printer facility at the health care facility as well as a professional technician to operate the 3D printer. Further, some of the additional constraints are listed below in Table- 1.

[006] The conventional mechanism for treating or healing fractures are cumbersome, heavy, and take at least 6 weeks to heal. Furthermore, they are inconvenient in terms of discomfort and stress involved with the healing process, and they may result in issues during cast removal, such as skin damage and limb swelling. Swelling of the part, activity limitation, decreased arterial blood flow, discomfort, nerve injury, and so on are some of the other drawbacks of the conventional cast.

[007] As a result, there is a need for a method or device that helps in healing fracture at a quicker pace to overcome the disadvantages of conventionally employed casting methods for bone healing. Furthermore, a fracture cast may require a desirable number of specific features, including but not limited to lightweight, all-fit adjustable for ready usage, water-resistant, flexible mobility, resizable according to size, easily removable, recyclable, and reusable with sterilization, and no need for a 3D scanner or printer. Although several fracture casts have been disclosed in the prior art, they do not provide the benefits of quicker, more controlled healing or configurable all-fit size to properly treat the fracture region.

[008] In another conventional mechanism, patent application W02015124900A1 discloses a thermoplastic article for orthopedic applications consisting of a substrate containing 57 to 95 weight percent of a thermoplastic polymer and 5 to 30 weight percent of wax, where the article is plastic at temperatures ranging from 40 °C to 60 °C. The usage of the article in conjunction with a computer-readable medium permits the article to be created when executed on a processor. [009] In yet another conventional mechanism, the patent application US20160213320A1 discloses an orthopedic support device comprising of a shell supporting a body portion. Further, the orthopedic support device includes one or more stimulators mounted on the shell to signal a wearer of the orthopedic support device to perform a muscular activity. The one or more stimulators are configured to communicate with a controller in order to control the one or more stimulators. Furthermore, the orthopedic support device comprises one or more sensors provided on an interior portion of the shell to capture biological activity data in relation to said body portion, the one or more sensors being adapted to store the biological activity data in a memory, the memory being in communication with the controller, in order to control the one or more stimulators on the basis of the biological activity data captured by the one or more sensors. This patent application suggests an orthopedic cast assembly composed of any suitable number of modular components and fasteners, each of which may be provided in any suitable shape and size, as may be easily understood by a skilled reader.

[0010] In yet another conventional mechanism, the patent application WO2016135604 Al discloses a method and apparatus comprising a band (26), one or more ultrasonic transducers (36a, 36b, 36c), and a controller (38), all of which are coupled to the band. The controller is configured to enable at least one of the ultrasonic transducers to transmit an ultrasonic wave towards the fracture of the bone.

[0011] In yet another conventional mechanism, patent US8043234 B2, discloses systems and methods for providing therapeutic treatment using vibrational stimulation, ultrasound stimulation, and electro-stimulation. This conventional mechanism enables combined therapeutic treatment by providing one or a combination of vibrational, ultrasound, and/or electro-stimulation to a patient. The combined therapeutic treatment provides a more flexible and effective treatment of bone-loss-related and other ailments and conditions.

[0012] In yet another conventional mechanism, patent US8613716 B2 discloses a custom device and a method for fabricating the custom device, which involves marking a body with reference points and/or other indicators. Further, the custom device obtains multiple images of the body from multiple angles. These images are used to determine the contours of the body and other markings are located and used to design the custom device. The custom device can be fabricated as a single piece structure or in multiple pieces that are combined to form the custom device.

[0013] In yet another conventional mechanism, a non-patent reference, (https://www.technologyreview.com/2016/07/25/70590/you-can-get-a-3-d- printed-cast-for-a-broken-bone/) discloses a 3D Printed Cast for a broken bone. The reference suggests an open-lattice plastic design that is customized for the individual patient. These 3D printed casts are waterproof, more comfortable, and may even help the bones heal faster.

[0014] In yet another conventional mechanism, a non-patent reference (http://www.medicaldaily.com/3d-printed-osteoid-cast-built-ultrsound-may-heal- bones-38-faster-278188) discloses a “3D-Printed Osteoid Cast with Built-In Ultrasound May Heal Bones 38% Faster-”. This Osteoid medical cast has a bone stimulation system known as low intensity pulsed ultrasound (LIPUS). This system operates by applying “transcutaneous acoustic energy” to the fractured bones.

[0015] In yet another conventional mechanism, a non-patent Reference (https://www.ncbi.nlm.nih.gov/pmc/articles/PMC2762261/) discloses a "Low- intensity pulsed ultrasound: Fracture Healing". This reference discloses about the use of LIPUS to accelerate the healing process by influencing all four stages of fracture healing. The existing art discloses a variety of fracture cast products, such as Cortex Cast for healing broken bones; Osteoid (by Turkish industrial designer Karasahin), which is a 3D-printed-cast-that-can-heal-your-bones-40-80-faster; Zdavprint, a printed cast product by a Russian; "Exovite," a product for broken- bone -healing; and 3D-printed-cast by "Michigan Technological University". The existing art also discloses information about "Novacast" (https ://www . sciencedaily .com/releases/2016/04/ 160414145348.htm) from a Mexican start-up and "Xkelet" (https://www.xkelet.com/). However, none of these references provide a conveniently available fracture cast with faster, controlled healing. [0016] All of the traditional mechanisms discussed above, as well as 3D Printed casts, use alternative therapeutic regimens to aid in faster healing. However, they are heavy and bulky, causing skin trauma and itchiness, are not water resistant, non-recyclable, and not reusable due to sizing issues, and may cause complications during cast removal.

[0017] The following are the limitations, inadequacies, disadvantages, an d issues present in the conventional casts.

• Heavy weight and bulky

• causes skin trauma and itching

• It causes swelling of the body part

• Not water or sweat resistance

• Restricts user activity

• Impaired Arterial Supply

• causes pain

• causes plaster sores

• causes nerve damage

• causes complications during cast removal: Injury to skin, Swelling of the Limb after Cast Removal.

• Non-recyclable

• The duration for getting a 3D cast is more than 5 hours

• It requires investment in a 3D printer facility at the healthcare center and a skilled technician to use the 3D printer

• The 3D printed fracture cast cannot be used after the edema/swelling has reduced.

• Non reusable 3D printed cast.

Table-1

[0018] In light of the aforementioned limitations, deficiencies, drawbacks, and concerns, there is an urgent need for a fracture casting device that is lightweight, washable and ventilated, reusable, recyclable, and easily removable, resizable according to size, is an all-fit fracture cast, and provides faster controlled healing.

OBJECT OF INVENTION

[0019] The principal object of the embodiments herein is to provide a segmented all-fit adjustable fracture cast for treating bone fractures, wherein the segmented all-fit adjustable fracture cast is simple to use, reusable, and recyclable.

SUMMARY OF THE INVENTION

[0020] Accordingly, the embodiments herein provide a segmented all-fit adjustable fracture cast for treating bone fractures. The segmented all-fit adjustable fracture cast comprises a rail mechanism with at least one pair of main rails. The at least one pair of main rails includes a pair of top main rails and a pair of bottom main rails. The rail mechanism is configured to carry an assemblage of one or more sliding rail holders, wherein each of the one or more sliding rail holders is configured to carry a pair of mid rails on a turret mechanism mounted on each of the one or more sliding rail holders. Further, the segmented all-fit adjustable fracture cast includes an adjustable stub, wherein the adjustable stub is configured to secure a fractured portion of a hand. Furthermore, the segmented all-fit adjustable fracture cast includes one or more stub screws. The one or more stub screws are configured to adjust a stub from time to time based on the swelling of the fractured portion of the hand. Further, the segmented all-fit adjustable fracture cast includes an adjustable top hand segment cast, wherein the adjustable top hand segment cast is coupled with the at least one pair of main rails. Further, the segmented all -fit adjustable fracture cast includes an adjustable bottom hand segment cast. The adjustable bottom hand segment cast is coupled with the at least one pair of main rails.

[0021] In an embodiment, the adjustable top hand segment casts, and adjustable bottom hand segment casts configured to hold the fractured portion of the hand in position.

[0022] In an embodiment, the adjustable top hand segment casts and adjustable bottom hand segment casts configured to accommodate variation in the fractured portion of hand size using one or more screws present on the adjustable top hand segment casts and adjustable bottom hand segment casts.

[0023] In an embodiment, the rail mechanism configured to allow the one or more sliding rail holders to move along the length of at least one pair of main rails to the position of a fracture on a forehand.

[0024] In an embodiment, the one or more sliding rail holders along with the assemblage of the pair of mid rails are configured to position before and after a bone fracture to immobilize the bone fracture by holding bones in position using the adjustable stub(s).

[0025] In an embodiment, wherein the pair of mid rails are configured to slide within a turret to accommodate a variation in arm width. The turret is configured to swivel around the turret screw to accommodate an orientation due to a difference in inner and outer arm lengths.

[0026] In an embodiment, wherein the pair of top main rails and bottom main rails configured to place over the fractured portion of the hand by strappers (19) that pass-through strapper slots and are locked in tension by strapper lock. [0027] In an embodiment, the segmented all-fit adjustable fracture cast is integrated with ultrasound to allow for faster, controlled healing of sprains and inflamed tendons and ligaments.

[0028] In an embodiment, the segmented all-fit adjustable fracture cast is configured with one or more fasteners to operate between a fastening configuration and an unfastening configuration.

[0029] In an embodiment, the segmented all-fit adjustable fracture cast is manufactured using three-dimensional printing. The three-dimensional printing uses at least one of plastic, fiberglass, or any other material with the appropriate degrees of flexibility, durability, water and heat resistance, and ease of production.

[0030] In an embodiment, the segmented all-fit adjustable fracture cast is reusable and recyclable.

[0031] In an embodiment, wherein an exterior surface/shell of the segmented all-fit adjustable fracture cast is printed with at least one of a specification data, patient-related information, decorative design, and LED illumination.

[0032] In an embodiment, the segmented all-fit adjustable fracture cast assembly and/or modular components can be interchangeable (for aesthetic purposes, repair, change of size, change of shape, etc.).

[0033] In an embodiment, the segmented all-fit adjustable fracture cast (100) provides decorative features. The segmented all-fit adjustable fracture cast (100) assembly and/or modular components can be interchangeable, for example, to better fit aesthetically with a patient’ s outfit for a particular occasion, or to change components for practical purposes based on a particular activity.

[0034] In an embodiment, the exterior surface/shell of the segmented allfit adjustable fracture cast can be printed with content such as specification data, patient related information, decorative design, or the like.

[0035] In an embodiment, the segmented all-fit adjustable fracture cast is formed of multiple modular components and can be produced into various complementary components. [0036] In an embodiment, the segmented all-fit adjustable fracture cast includes a segmented cast with a substantially rail configuration for supporting the healing of the body portion. In one embodiment, a resilient material is used to manufacture the segmented all-fit adjustable fracture cast.

[0037] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Embodiments herein are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The example embodiments herein will be better understood from the following description with reference to the drawings, in which:

[0039] FIG. 1 is a schematic diagram illustrating a perspective view of a segmented all-fit adjustable fracture cast/orthopedic segmented cast for treating bone fractures, according to an embodiment as disclosed herein;

[0040] FIG. 2 is a schematic diagram illustrating mountings of the segmented all-fit adjustable fracture cast to hold a hand in position by an adjustable top and a bottom hand segment casts, according to an embodiment as disclosed herein;

[0041] FIG. 3 is a schematic diagram illustrating the segmented all-fit adjustable fracture cast having a stub screw and a stub for adjusting based on the healing of the wound (edema/swelling), according to an embodiment as disclosed herein.

[0042] FIG. 4 is a schematic diagram illustrating a rail mechanism enabling the one or more sliding rail holders to move along the length of the main rail to a position of the fracture on a forehand, according to an embodiment as disclosed herein;

[0043] FIG. 5 is a schematic diagram illustrating the segmented all-fit adjustable fracture cast, wherein a pair of rail holders, as well as the assembly of the mid rails, are positioned before and after the bone fracture to immobilize the fracture, according to an embodiment as disclosed herein;

[0044] FIG. 6 is a schematic diagram illustrating the segmented all-fit adjustable fracture cast with a mechanism to accommodate variation in arm width, according to an embodiment as disclosed herein; and

[0045] FIG. 7 is a schematic diagram illustrating a pair of top main rails and a pair of bottom main rails, according to an embodiment as disclosed herein.

DETAILED DESCRIPTION OF THE INVENTION

[0046] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the nonlimiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted, so as not to unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein can be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0047] The embodiments herein provide a segmented all-fit adjustable fracture cast for treating bone fractures. The segmented all-fit adjustable fracture cast comprises a rail mechanism with at least one pair of main rails. The at least one pair of main rails includes a pair of top main rails and a pair of bottom main rails. The rail mechanism is configured to carry an assemblage of one or more sliding rail holders, wherein each of the one or more sliding rail holders is configured to carry a pair of mid rails on a turret mechanism mounted on each of the one or more sliding rail holders. Further, the segmented all-fit adjustable fracture cast includes an adjustable stub, wherein the adjustable stub is configured to secure a fractured portion of a hand. Furthermore, the segmented all-fit adjustable fracture cast includes one or more stub screws. The one or more stub screws are configured to adjust a stub from time to time based on the swelling of the fractured portion of the hand. Further, the segmented all-fit adjustable fracture cast includes an adjustable top hand segment cast, wherein the adjustable top hand segment cast is coupled with the at least one pair of main rails. Further, the segmented all-fit adjustable fracture cast includes an adjustable bottom hand segment cast. The adjustable bottom hand segment cast is coupled with the at least one pair of main rails. In an embodiment, the adjustable top hand segment casts, and adjustable bottom hand segment casts configured to hold the fractured portion of the hand in position. In an embodiment, the adjustable top hand segment casts and adjustable bottom hand segment casts configured to accommodate variation in the fractured portion of hand size using one or more screws present on the adjustable top hand segment casts and adjustable bottom hand segment casts. Referring now to the drawings, and more particularly to FIGS. 1 through 7, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.

[0048] FIG. 1 is a schematic diagram illustrating a perspective view of a segmented all-fit adjustable fracture cast/orthopedic segmented cast for treating bone fractures, according to an embodiment as disclosed herein. The segmented allfit adjustable fracture cast (100) comprises a rail mechanism with at least one pair of main rails (1) (5). The at least one pair of main rails (1) (5) includes a pair of top main rails (1) and a pair of bottom main rails (5). The rail mechanism is configured to carry an assemblage of one or more sliding rail holders (6), wherein each of the one or more sliding rail holders (6) is configured to carry a pair of mid rails (2) on a turret (3) mechanism mounted on each of the one or more sliding rail holders (6). The pair of mid rails (2) configured on each of the one or more sliding rail holders (6) can be locked in position by a turret screw (4) and can be slide along the length of the at least one pair of main rails (1) (5). The pair of mid rails (2) configured on each of the one or more sliding rail holders (6) includes an adjustable fork/clamps/stub (13) to secure a fractured portion appropriately to a required profile. Further, the segmented all-fit adjustable fracture cast (100) includes one or more stub screws (12). The one or more stub screws are configured to adjust a stub (13) from time to time based on the swelling of the fractured portion of the hand.

[0049] In an embodiment, the segmented all-fit adjustable fracture cast (100) can be available as an add-on sleeve to cover the length of a body part based on a medical requirement. In an embodiment, the segmented all-fit adjustable fracture cast (100) can be made up of light-weight material that is suitable for human skin.

[0050] In an embodiment, the segmented all-fit adjustable fracture cast is integrated with ultrasound (not shown) to allow for faster, controlled healing of sprains and inflamed tendons and ligaments.

[0051] FIG. 1 show exemplary units of the segmented all-fit adjustable fracture cast (100), but it is to be understood that other embodiments are not limited thereto. In other embodiments, the segmented all-fit adjustable fracture cast (100) may include less or more number of units. Further, the labels or names of the units are used only for illustrative purposes and does not limit the scope of the invention. One or more units can be combined together to perform the same or substantially similar function as in the segmented all-fit adjustable fracture cast (100).

[0052] FIG. 2 is a schematic diagram illustrating mountings of the segmented all-fit adjustable fracture cast (100) to hold a hand in position by an adjustable top and a bottom hand segment cast (8,10) (9,11), according to an embodiment as disclosed herein. The segmented all-fit adjustable fracture cast (100) is designed to hold the hand in place with the assistance of the adjustable top hand segment cast and the adjustable bottom hand segment cast (8,10) (9,11). The adjustable top hand segment cast (8,10) and adjustable bottom hand segment cast (9,11) are equipped with hand adjuster flanges (14) that will carry an adjusting screw (15) that connects the top outer hand (8) and top inner hand (10) together, as well as the bottom outer hand (9) and bottom inner hand (11). The adjusting screw (15) can help in adjusting the hand width and ensuring that it completely fits the hand. In an embodiment, a rail mount flange (16) of the segmented all-fit adjustable fracture cast (100) connects to the main rail (1) at the wrist and links the top inner hand (10) and bottom inner hand (11), firming the hands.

[0053] FIG. 3 is a schematic diagram illustrating the segmented all-fit adjustable fracture cast (100) having a stub screw (12) and a stub (13) for adjusting based on the healing of the wound (edema/swelling), according to an embodiment as disclosed herein. The segmented all-fit adjustable fracture cast (100) can be configured with one or more stub screws (12) and the stub (13). In an embodiment, the one or more stub screws (12) and the stub (13) can be adjusted from time to time based on the healing of the wound (edema/swelling). The one or more stub screws (12) and the stub (13) enables the segmented all-fit adjustable fracture cast (100) to adjust to the required profile for the fractured portion of hand by the stub holder (17) tilting hinged on a connector holes/slot (21).

[0054] FIG. 4 is a schematic diagram illustrating a rail mechanism enabling the one or more sliding rail holders (6) to move along the length of the main rail (1) to a position of the fracture on a forehand, according to an embodiment as disclosed herein. The rail mechanism enables the one or more sliding rail holders (6) to move along the length of the main rail (1) to the position of the fracture on the forehand.

[0055] FIG. 5 is a schematic diagram illustrating the segmented all-fit adjustable fracture cast (100), wherein a pair of rail holders (6), as well as the assembly of the mid rails (2), are positioned before and after the bone fracture (18) to immobilize the fracture, according to an embodiment as disclosed herein. According to the embodiments, the rail holders (6), as well as the assembly of the mid rails (2), are positioned before and after the bone fracture (18) to immobilize the fracture by keeping the bones in place using the stubs (13). This mechanism substantially conforms to the shape of the body part. Further, this mechanism enables relief along the interior section to provide one or more pressure zones in relation to an injury location in the body portion. This helps to align the bones during a body -part muscle contraction.

[0056] In an embodiment, the relief includes a protrusion, which is substantially aligned with the injury location (18) to exert pressure on the injury location. The relief includes protrusion proximally and distally from the injury location to restore alignment of the body portion.

[0057] FIG. 6 is a schematic diagram illustrating the segmented all-fit adjustable fracture cast (100) with a mechanism to accommodate variation in arm width, according to an embodiment as disclosed herein. According to an embodiments, the mid rails (2) slide within the turret (3) to accommodate the variation in the arm width (dotted blue arrows). In an embodiment, the turret (3) can swivel around (circular blue arrow) the turret screw (4) to accommodate the orientation due to a difference in the inner arm length and outer arm length. Once the mid rails (2) are in position, the turret screw (4) is tightened to lock the turret (3) and the mid rail (2) in position for a patient.

[0058] FIG. 7 is a schematic diagram illustrating a pair of top main rails (1) and a pair of bottom main rails (5), according to an embodiment as disclosed herein. According to an embodiments, the top main rails (1) and bottom main rails (5) can be held in position over the fractured arm by strappers (19). The strappers

(19) can pass through the strapper slots (22) and locked in tension by strapper lock

(20). In an embodiment, a similar mechanism can be used to hold the top main rails (1) and bottom main rails (5) in position.

[0059] According to the embodiments, the segmented all-fit adjustable fracture cast (100) can be adjusted to a shape based on a located region (s) to provide additional pressure and/or support in respect to the located region (s) of the body portion to be treated.

[0060] According to the embodiments, the at least one pair of main rails (1) (5), can be configured to carry the segmented cast made up of modular components (2), (3), (6), (12), (13) and (17), as well as a fastening system (4) and (19) that comprises fasteners (20) for holding the rails (1), (5), and modular components (2), (3) and (13) around the body part. The fasteners (4) and (12) are configured to switch between a fastening configuration in which the corresponding modules (2), (3), (6), (13) and (17) are positioned to support the body portion and an unfastening configuration in which the corresponding modules (2), (3), (6), (13) and (17) are from supporting the body portion. [0061] In an embodiment, wherein the segmented all-fit adjustable fracture cast (100) configured with unfastening configuration and the fastening configuration. The unfastening configuration frees the modules from one another (i.e., unassembled configuration). The fastening configuration binds the modules together (i.e., assembled configuration) about the body portion. In some embodiments, a fastener remains connected to the modules even in the unfastening configuration.

[0062] In an embodiment, the fasteners (19), (20) or connectors or the fastening system (22), (19), (20) can be replaced by any other appropriate component (s), such as an elastic band or the like.

[0063] In one embodiment, the segmented all-fit adjustable fracture cast (100) can be configured with a modular orthopedic support assembly comprising: modular components configured to form the segmented all-fit adjustable fracture cast (100) around a body portion for supporting said body portion. The segmented all-fit adjustable fracture cast (100) can also be equipped with one or more fasteners (i.e., a fastening system) to secure the modular components to the body portion.

[0064] According to the embodiments, the segmented all-fit adjustable fracture cast (100) assembly can be temporarily removed and reinstalled as needed. In an embodiment, the modules and fastener(s) are configured to allow the patient, or a person assisting the patient, to assemble or disassemble the segmented all-fit adjustable fracture cast (100) about the body portion without the need for specialized skills, such as consulting a medical professional and/or travelling to a medical facility or the like.

[0065] In an embodiment, the segmented all-fit adjustable fracture cast (100) assembly and/or modular components (2), (12), (13), (17) can be interchangeable (for aesthetic purposes, repair, change of size, change of shape, etc.).

[0066] In an embodiment, the segmented all-fit adjustable fracture cast (100) can be composed with any number of modular components and fasteners to support a particular body member. The modular components can be provided in any suitable shape and size based on the requirement. [0067] In an embodiment, the segmented all-fit adjustable fracture cast (100) can be easily removed and reinstalled about the body portion. It is to be understood that the above -de scribed the segmented all-fit adjustable fracture cast (100) can be combined with any compatible feature of the afore -mentioned orthopedic support assembly.

[0068] In an embodiment, an exterior surface/shell of the segmented allfit adjustable fracture cast (100) can be printed with a content such as specification data, patient related information, decorative design, and LED illumination or the like.

[0069] According to an embodiments, the segmented all-fit adjustable fracture cast (100) can be made through three-dimensional printing. It is to be understood that according to the embodiments, the segmented all-fit adjustable fracture cast (100) can be made of one or more modular components.

[0070] In an embodiment, the three-dimensional printing of the segmented all-fit adjustable fracture cast (100) can be made through a suitable plastic or fiberglass material, and/or any other material having a suitable weight, flexibility, and durability.

[0071] In one embodiment, the segmented all-fit adjustable fracture cast (100) is configured with proper ventilation. The segmented all-fit adjustable fracture cast (100) does not respond to body sweats and fluids and eliminates skin damage and itching.

[0072] According to certain embodiments, the stub (13) of the segmented all-fit adjustable fracture cast (100) assembly is made of a resilient material that applies radial pressure to the body in its original configuration. The periodic contraction of the stub (13) in the radial direction in one embodiment stimulates bone development and hence permits limb healing. The radial contraction is progressive and limited in range, which thus prevents bone misalignment. In one embodiment, the segmented all-fit adjustable fracture cast (100) assembly can additionally contain a detachable component with a resilient material providing consistent longitudinal pressure for bone development enhancement. [0073] The embodiments herein provide an orthopedic support assembly, such as a segmented fracture cast, orthosis, brace, or splint assembly, or any other orthopedic support assembly, having a segmented fracture cast mechanism to facilitate healing of a body part.

[0074] The embodiments herein provide a method of manufacturing the segmented all-fit adjustable fracture cast (100) assembly for supporting a fractured body portion, comprising the following steps:

[0075] In an embodiment, to manufacture the orthopedic support device, a three-dimensional printing of the acquired model is performed. In one embodiment, three-dimensional printing is done with plastic, fiberglass, or any other material that has the appropriate degrees of flexibility, durability, water and heat resistance, ease of production, and integration of monitoring and stimulation technologies.

[0076] In an example, three-dimensional printing includes printing modular components and attaching the orthopedic support device to the body portion using attachment means on the modular components.

[0077] The segmented all-fit adjustable fracture cast (100) is reusable and recyclable. The segmented all-fit adjustable fracture cast (100) can be reused after sterilization. The segmented all-fit adjustable fracture cast (100) is constructed of a recyclable cast material. As a result, the segmented all-fit adjustable fracture cast (100) can be recycled.

[0078] In an embodiment, the segmented all-fit adjustable fracture cast (100) assembly and/or modular components can be interchangeable (for aesthetic purposes, repair, change of size, change of shape, etc.).

[0079] In an embodiment, the segmented all-fit adjustable fracture cast (100) provides decorative features. The segmented all-fit adjustable fracture cast (100) assembly and/or modular components can be interchangeable, for example, to better fit aesthetically with a patient’ s outfit for a particular occasion, or to change components for practical purposes based on a particular activity. [0080] In an embodiment, the exterior surface/shell of the segmented allfit adjustable fracture cast (100) can be printed with content such as specification data, patient related information, decorative design, or the like.

[0081] In an embodiment, the segmented all-fit adjustable fracture cast (100) is formed of multiple modular components and can be produced into various complementary components.

[0082] In an embodiment, the segmented all-fit adjustable fracture cast (100) includes a segmented cast with a substantially rail configuration for supporting the healing of the body portion. In one embodiment, a resilient material is used to manufacture the segmented all-fit adjustable fracture cast.

[0083] According to the embodiments disclosed herein, the segmented allfit adjustable fracture cast (100) provides the advantages as follows:

[0084] The segmented all-fit adjustable fracture cast (100), according to implementations of the present invention, provides the following advantages:

[0085] The segmented all-fit adjustable fracture cast (100) provides a segmented fracture cast that is all-fit adjustable fracture cast for immediate use and is easily available, requiring no investment in a 3D scanner and printer.

• The segmented all-fit adjustable fracture cast (100) can be resized to meet the patient's size, avoiding the complications that can occur when fitting a customized cast due to swelling.

• The segmented all-fit adjustable fracture cast (100) is light, washable, and ventilated to prevent skin stress and itching.

• The segmented all-fit adjustable fracture cast (100) is simple to remove, lowering the possibility of complications during cast removal.

• The segmented all-fit adjustable fracture cast (100) is water-resistant and provides flexible mobility.

• The segmented all-fit adjustable fracture cast (100) has an integrated ultrasound device for faster, more controlled healing.

• The segmented all-fit adjustable fracture cast (100) does not necessitate the services of a 3D printer technician at the healthcare facility. • The segmented all-fit adjustable fracture cast (100) and/or its components can be manufactured remotely and transported to the patient or a clinic in proximity to the patient, which is advantageous.

[0086] The foregoing description related to the segmented all-fit adjustable fracture cast (100) has been described with reference to specific embodiments, but additions, deletions, and alterations to these embodiments are possible without departing from the scope of the invention. The same processes can be used to design and fabricate shoulder spica, hip spica, spica casts, Pavlik brace, clubfoot casting, metatarsus adductus casting, blounts disease casting/bracing, ankle foot orthosis, pediatric ankle casts, pediatric walking casts, spine TLSO braces, halo body cast, cervical collar, torticollis bracing, and other medical devices.

[0087] The foregoing description of the specific embodiments related to the segmented all-fit adjustable fracture cast (100) can be adapted to various applications such as custom chairs, seats, saddles, athletic equipment, shoes, padding, helmets, motorcycle and bicycle seats, handlebars, and handgrips, and so forth. Animal braces and casts, as well as tailored saddles for horses and equestrians, can be made using the described apparatus and method. Although the custom castings, braces, and devices mentioned involve a variety of components, it is generally established that these components, as well as the stated arrangement, may be changed and reconfigured in a variety of ways.

[0088] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

Claims

We claim:

1. A segmented all-fit adjustable fracture cast (100) for treating bone fractures, the segmented all-fit adjustable fracture cast (100) comprising: a rail mechanism with at least one pair of main rails (1) (5), wherein the at least one pair of main rails (1) (5) includes a pair of top main rails (1) and a pair of bottom main rails (5), wherein the rail mechanism configured to carry an assemblage of one or more sliding rail holders (6), wherein each of the one or more sliding rail holders (6) configured to carry a pair of mid rails (2) on a turret (3) mechanism mounted on the each of the one or more sliding rail holders (6); an adjustable stub (13), wherein the adjustable stub (13) configured to secure a fractured portion of a hand; one or more stub screws (12), wherein the one or more stub screws configured to adjust a stub (13) from time to time based on a swelling of the fractured portion of hand; an adjustable top hand segment casts (8, 10), wherein the adjustable top hand segment casts (8, 10) coupled with the at least one pair of main rails (1) (5); and an adjustable bottom hand segment casts (9, 11), wherein the adjustable bottom hand segment casts (9, 11) coupled with the at least one pair of main rails (1) (5).

2. The segmented all-fit adjustable fracture cast (100) as claimed in claim 1, wherein the adjustable top hand segment casts (8, 10) and adjustable bottom hand segment casts (9, 11) configured to hold the fractured portion of the hand in position.

3. The segmented all-fit adjustable fracture cast ((100)) as claimed in claim 1, wherein the adjustable top hand segment casts (8, 10) and adjustable bottom hand segment casts (9, 11) configured to accommodate variation in the fractured portion of hand size using one or more screws (15) present on the adjustable top hand segment casts (8, 10) and adjustable bottom hand segment casts (9, 11). The segmented all-fit adjustable fracture cast (100) as claimed in claim 1, wherein the rail mechanism configured to allow the one or more sliding rail holders (6) to move along the length of at least one pair of main rails (1) (5) to the position of a fracture on a forehand. The segmented all-fit adjustable fracture cast (100) as claimed in claim 1, wherein the one or more sliding rail holders (6) along with the assemblage of the pair of mid rails (2) are configured to position before and after a bone fracture (18) to immobilize the bone fracture (18) by holding bones in position using the adjustable stub(s) (13). The segmented all-fit adjustable fracture cast (100) as claimed in claim 1, wherein the pair of mid rails (2) configured to slide within a turret (3) to accommodate variation in arm width, wherein the turret (3) configured to swivel around the turret screw (4) to accommodate an orientation due to a difference in inner and outer arm lengths. The segmented all-fit adjustable fracture cast (100) as claimed in claim 1, wherein the pair of top main rails (1) and bottom main rails (5) configured to place over the fractured portion of the hand by strappers (19) that pass-through strapper slots (22) and are locked in tension by strapper lock (20). The segmented all-fit adjustable fracture cast (100) as claimed in claim 1, wherein the segmented all-fit adjustable fracture cast integrated with ultrasound to allow for faster controlled healing of sprains and inflamed tendons and ligaments. The segmented all-fit adjustable fracture cast (100) as claimed in claim 1, wherein the segmented all-fit adjustable fracture cast configured with one or more fasteners to operate between a fastening configuration and an unfastening configuration. The segmented all-fit adjustable fracture cast (100) as claimed in claim 1, wherein the segmented all-fit adjustable fracture cast is manufactured using three-dimensional printing. The segmented all-fit adjustable fracture cast (100) as claimed in claim 10, wherein the three-dimensional printing uses at least one of plastic, fiberglass, or any other material with the appropriate degrees of flexibility, durability, water and heat resistance, and ease of production. The segmented all-fit adjustable fracture cast (100) as claimed in claim 1, wherein the segmented all-fit adjustable fracture cast is reusable and recyclable. The segmented all-fit adjustable fracture cast (100) as claimed in claim 1, wherein an exterior surface/shell of the segmented all-fit adjustable fracture cast (100) is printed with at least one of a specification data, patient related information, decorative design, and LED illumination.