The Problem

Every year, 178 million fractures occur worldwide.
While 34 million of them can be treated using splints, current solutions present a trade-off:

• Traditional plaster casts are cheap but heavy, uncomfortable, and unhygienic.
• Modern 3D-printed casts are comfortable but expensive and slow to produce.

This creates a market gap where patients must choose between comfort and affordability.

The Solution

FLONIX introduces a thermo-responsive splint system made from shape-memory materials that can be quickly molded around the patient’s limb without 3D scanning.

The solution delivers:

• Lightweight breathable structure
• Rapid clinical application
• Reusability and sustainability
• Optional ultrasound therapy to accelerate healing

By combining engineering innovation with a scalable business model, FLONIX aims to deliver modern orthopedic care without the high cost barrier.

Challenges Overcome

1. Shape Adaptability vs Structural Strength

Challenge: Ensuring the splint remains flexible during molding while becoming rigid enough to stabilize fractures.

Solution: Optimized lattice structures and thickness distribution to balance flexibility and strength.

2. Rapid Clinical Application

Challenge: Traditional 3D-printed casts require scanning and a long fabrication time.

Solution: Developed a flat-sheet thermo-activated design that can be molded directly onto the limb within minutes.

Engineering Process

The product was developed through an iterative engineering process:

1. Problem Analysis
2. Concept Development
3. CAD Modeling
4. Material Activation Study
5. Mechanical Structure Optimization
6. Prototype Testing