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Plaster has held bones since 1852. We built what comes next.
OrthoHeal makes FlexiOH® — a light-cured polymer immobilizer that is washable, breathable and removed without a saw. Invented by a surgeon, manufactured in Gujarat, used in more than fifty countries.
The most common injury in medicine, treated with a nineteenth-century bandage
- 178 million new fractures a year. 455 million people are living with the acute or long-term symptoms of one, costing 25.8 million years lived with disability. Global Burden of Disease Study 2019, Lancet Healthy Longevity.
- The standard of care is 174 years old. Antonius Mathijsen introduced the plaster-of-Paris bandage in 1852. It cannot get wet, it does not breathe, and it is removed with an oscillating saw.
- Fibreglass and thermoplastics changed the material, not the experience. Still not washable, still not breathable, still cut off.
- The cost is borne twice. Once by the patient — six weeks of itching, odour and washing around a limb — and once by the department, in saw time, saw injuries and re-casting.
new fractures a year
worldwide, GBD 2019
people living with one
acute or long-term symptoms
Why it has not been solved
A better cast has to be rigid enough to hold a reduction, soft enough to mould onto a limb, safe against skin, and quick enough — under fifteen minutes — to fit a routine workflow. Materials that do one tend to fail another. FlexiOH® cures under visible blue light, so it is soft when it goes on and rigid a few minutes later — the shape is locked to the reduction the surgeon achieved.
A platform, not a product
One curing technology, four product families, and an installed light in every cast room that uses them.
Light-cured polymer
A photo-curing resin sealed in silicone over a latex-free foam liner. Soft on the limb; rigid in three to five minutes under RizyCure's UV-free blue light. Washable, breathable, and removed with bone-cutting forceps — no saw, no dust, no noise.
Equipment pulls consumable
One RizyCure light is installed in the cast room; the immobilizers are single-use and reorder themselves. The light is what gets a department to try the system — the consumable is what makes it a business.
Four families
FlexiSplint® for urgent and post-operative care, FlexiOH® for conservative fracture management, FlexiCast® for remouldable casting, and FlexiBrace® for rehabilitation from Q4 2027 — across upper and lower limb, adult and paediatric.
What is defensible
- Patented light-cured polymer chemistry, developed in-house
- Exclusive licence to commercialise FlexiOH from the Government of India
- Vertically integrated manufacturing — resin, lattice and assembly under one roof
- Regulatory files already cleared in ten jurisdictions, each one a barrier behind us and in front of a follower
Shipping, cleared, and manufacturing at scale
immobilizers on patients
since commercial launch in 2020
countries served
from offices in Vadodara, Hamburg and Texas
manufacturing at Savli
occupied January 2025, scaling towards a million units a year
Regulatory position
Registration or listing with a regulator is not approval, clearance or endorsement. FlexiOH® is "US FDA listed"; CE marking is by declaration of conformity as a Class I device. Certificates and status by market →
Clinical evidence
- 108-patient retrospective cohort, 2026. Alignment at device removal was anatomic or near-anatomic in 103 of 104 fractures — 99.1%.
- Five-site Indian post-market study. 137 distal radius fractures; radiographic healing seen in all participants.
- National BioPharma Mission grant with BIRAC, for trials establishing equivalence with gold-standard immobilisation.
A decade of grants and national recognition
- 2015
BIRAC–SRISTI Gandhian Young Technological Innovation Award, presented at Rashtrapati Bhavan. Exclusive licence to commercialise FlexiOH® from the Government of India.
- 2016
Gold medal, Top 50 Innovations — DST–Lockheed Martin India Innovation Growth Programme. BIRAC Biotechnology Ignition Grant. CII Industrial Innovation Awards, Top 10 Promising Start-ups.
- 2018
BIRAC Biotechnology Industry Partnership Programme grant for pilot-scale production.
- 2022
Grand Challenges India grant, sponsored by the Bill & Melinda Gates Foundation, for paediatric deformity work.
- 2023
National Startup Awards 2022 — winner, Health & Wellness. ISO 13485:2016 certification by BSI.
- 2024
Ubharte Sitare export champions programme. SFDA registration, Saudi Arabia.
Who runs it
A brilliant team led by the founder — a physician-engineer with an MBBS and an MMST from IIT Kharagpur, who invented FlexiOH during the Stanford India Biodesign fellowship at AIIMS Delhi. The advisory bench includes that fellowship's director, an AIIMS orthopaedic spine surgeon, an IIT Delhi design professor, and a former president of Tata AutoComp Systems.
Rather see it first?
The technology page explains how the polymer cures; the evidence page holds every certificate and paper.