The BOOMcast is a homegrown work project. It's inspired by an earlier project, HASHcast, a 3d-printed printed cast with a fun social twist. Back during May, one of our friends, Mike North, broke his fibula and had to wear a cast. Mike travels a lot and since the change in cabin pressure during flight can cause swelling, the prospect of wearing a regular fixed cast for a couple of months was daunting. So Mike reached out and we started collaborating on the BOOMcast. After a couple of meetings, we came up with a plan. In addition to it's primary function as a removable cast, we wanted the BOOMcast to help in the recovery process by recording gait and pressure data, and making that data easily available to doctors. And since breaking a leg can be a real bummer, we also built in some fun features like LED lighting and a sound system.
Ultimately the BOOMcast was a sprawling project, with many outside contributors, including Intel and Boombotix. The BOOMcast touched pretty much every aspect of product design - mechanical engineering, industrial design, embedded development, cloud integration, and mobile development. It's a testament to the amazing team I work with that we pulled this off in just three weeks. At FATHOM, six engineers and designers worked on BOOMcast, including Ava DeCapri, Alexei Samimi, Bethany Casarez, Aaron Porterfield, Veronica De La Rosa, and me. Other friends that contributed to BOOMcast include Skyler Brungardt and Zach Heineman. Intel provided hardware and valuable lessons they learned from a similar project, the Smart Splint. Boombotix donated the sound system we used in the version we built for Mike. Finally, none of this would have been possible without FATHOM's awesome marketing team for spearheading this project.
All of these files are available for download. If you'd like to join FATHOM's A360 hub and contribute, please send me an email.
Total printing time was about 112 hours -- almost 5 days.
After printing and cleaning the parts, it should be fairly obvious how they fit together. The wiring diagram is attached. There's quite a bit of wiring, it's tedious but not difficult.