This thesis presents PressSeal, a wearable sensing device designed to monitor forearm volume changes during fracture healing within an immobilization device. Swelling or shrinkage caused by edema or muscle atrophy can compromise cast fit and lead to complications such as compartment syndrome, pressure sores, and non-union. Current assessment methods rely on subjective evaluation and frequent clinical check-ups. An objective, remote monitoring approach could reduce follow-up visits and help prevent cast fit–related complications.

The PressSeal system integrates an air-filled pocket within a forearm sleeve, connected to a pressure sensor module (MPS20N0040D-D with HX710 amplifier) interfaced with an Arduino Nano 33 IoT. Skin–cast surface pressure readings are transmitted via Wi-Fi to the Arduino IoT Cloud and displayed in the Arduino Remote app, enabling objective, real-time monitoring and alerts for patients and clinicians when cast fit is compromised.

Prototype evaluation with four participants included comfort and functionality testing. Results showed the device to be lightweight, non-restrictive, and capable of detecting pressure variations with an accuracy of +/- 2.5 mmHg, sufficient to identify high-risk cast conditions. These findings demonstrate the feasibility of integrating PressSeal into fracture treatment. Although further clinical validation is needed, PressSeal offers a promising, low-cost, and user-friendly solution to enhance patient safety and reduce the clinical burden of fracture management.