Fathom is hiring for multiple positions across our 11 nationwide sites! To see all open positions, click here.

logo fathom

Boomcast

BOOMcast 3D Printed Leg Cast / / Wearable Tech Project

BOOMCAST-Project-Pyra-3D-Printing-Leg-Cast-Mike-North-1.jpg
BOOMCAST-Featured-on-ITM-Mike-North-BoomCast-Media2.jpg

NORTH & Fathom TAKE MEDICAL TO THE CLOUD / / Internet of Things (IoT) 3D Printed Leg Cast Realized

BOOMcast, created by Fathom for Mike North of Prototype This! And Outrageous Acts of Science on television, is a 3D printed cast with embedded electronics that enable a doctor to monitor the leg’s physical state from anywhere in the world. The cast allows North to maintain an active, enjoyable lifestyle that doesn’t compromise the healing process. Outfitted with pressure sensors, bluetooth speakers, LED lights, gyroscope, accelerometer and WIFI enabled Intel Edison, the BOOMcast is a true demonstration of how wearable technologies can be used for innovative medical purposes. To sum it up as Mike North puts it, “We call it the BOOMcast and this thing is badass.”

BOOMCAST-BoomCast-ppt-callouts-201506-layers2.jpg

CREATING BOOMCAST

When North broke his fibula, he immediately understood that none of the traditional cast options would be conducive to his personal and professional needs. As a TV host who travels frequently and an overall active human being, North needed a durable and easily removable cast. North enlisted help from Fathom to create a 3D printed cast that integrates technology from industry-leading companies like Intel and Google. The BOOMcast is programmed to deliver medical information to North’s doctor, play music from his phone, map pressure and audio data into LED lights that convey information for North’s edification and other extensive auxiliary features:

  • 3D-printed body and functional ratcheting straps (FDM Nylon 12 for impact strength and durability)

  • Sole of cast built in PolyJet multi-materials (rigid substructure with rubber-like cushioning)

  • Custom fit from digital body scan (FARO ScanArm)

  • Bluetooth-enabled speakers by Boombotix

  • Intel Edison (WiFi-enabled) powered by SparkFunAdafruit, and Arduino

  • Gyroscope, accelerometer and magnetometer

  • Force-sensitive resistors

  • Real-time data transfer to the cloud

  • Multi-color LED feedback

  • Hardware inserts

  • Additive manufacturing equipment used include Fortus 900mc and Objet500 Connex3


The BOOMcast was 3D printed in Nylon 12, a performance thermoplastic with excellent impact strength and durability. The BOOMcast includes four Force-Sensitive Resistors (FSRs) that record the contact pressure along the leg to indicate whether the healing bone has exceeded the doctor’s recommended load-bearing conditions.Externally, the most immediately noticeable feature is the speaker system. Broken legs often leave patients on the sideline of the party, but with the BOOMcast, the party goes to them. The cast’s fully functional speaker projects any music North desires and has a double-stomp function that provides a hands-free way to change tracks. The speakers are also programmed to exude inaudible low-frequency tones that research has indicated will facilitate the healing of the fractured bone.Beyond the electronic components, the BOOMcast utilizes additive manufacturing technologies to create an overall superior cast than standard offerings. This one-of-a-kind leg cast is removable, lightweight, comfortable and durable while also being travel-friendly as it expands to account for swelling that occurs with pressure changes during commercial flights.BOOMCAST-boomcast-feature3_940px.jpg

The BOOMcast is just one of many exciting projects developed at Fathom. Be sure to follow our blog for the latest on additive manufacturing technologies and applications!

Open Source Information: Mobile App (GitHub) / / Edison App (GitHub)  // DIY (Instructables)


MEDIA DOWNLOADS

For more information on this story, contact Fathom Media Relations.

Comprehensive Capabilities for Rapid Manufacturing

At Fathom we offer a unique advantage of speed and agility-our experts help companies go from concept to prototype to manufacturing in ways not previously possible. 

90+ Machines  
SLS / / Two-day  SLA / / Next-day 
FDM / / Next-day DMLS / / Three-day 
PolyJet / / Same-day MJF / / Two-day
   

Get A Quote

30 Second Quotes
Prototype Tool / / As soon as 10 days
10K Parts / / 10 days
Production Tool / / As soon as 3 weeks
 

Get A Quote

3 & 5 Axis Milling & Turning
(Plastics, Composites and Metals)

Tolerance Accuracy Range
from +/-0.001″ to 0.005″

Get A Quote

Injection Molding Adjacent
without High Costs of Metal Tools

Most Commonly Used for High-Volume
Prototyping & Bridge to Production

Get A Quote

Finishing, Production Painting and Color Matching

Assembling, Including Embedded Electronic
Components, Threaded Inserts, and More

Get A Quote

CAD, DFAM and DFM Services

Apply Methods to Increase Speed
and Decrease Total Cost

Get A Quote

Highly Trained Staff / / Full-Time & Part-Time
Support as Short-Term & Long-Term Strategy

Decrease Downtime with Customizable
Staffing Accelerates Implementation

Get A Quote

Let’s get started.

Fathom is driven by advanced technologies and methods that enhance and accelerate today’s product development and production processes.

GET YOUR 30 SECOND QUOTE

Across National
Time Zones

Precision manufacturing
from coast to coast.

HEADQUARTERS //
1050 Walnut Ridge Drive
Hartland, WI 53029
877-FATHOM-8

ARIZONA
444 W. 21st St. Ste. 101
Tempe, AZ 85282
480-966-2300

CALIFORNIA
46758 Lakeview Blvd
Fremont, CA 94538

COLORADO
7770 Washington St.
Denver, CO 80229
303-288-6855

FLORIDA
14000 N.W. 58th Court
Miami Lakes, FL 33014
305-889-3280

ILLINOIS
1207 Adams Drive
McHenry, IL 60051
815-385-7500

1401 Brummel Ave
Elk Grove, IL 60007
847-952-8088

MINNESOTA
13758 Johnson Street NE
Ham Lake, MN 55304
763-755-7575

NEW YORK
1920 Slaterville Rd.
Ithaca, NY 14850
607-277-7070

401 W. Shore Blvd.
Newark, NY 14513
315-331-7680

TEXAS
1513 Sam Bass Rd.
Round Rock, TX 78660
512-255-1477

fathom yellow color logo