During summer of 2014, Dr. Pankaj (Physician),Nikhil ( engineer) and Devanshi (designer) were assembled into a interdisciplinary team as School of international Biodesign intern (previously known as Stanford India Biodesign) at AIIMS -Delhi. With Objective to find a need in orthopedics, Team explored and stratified ~160 observations. What team found attractive is problems occurring with current orthopedic casts i.e POP,Glass fiber cast. There are many unsolved problems in casts such as Itching, irritation, bad odor, continuous discomfort, non washability, skin related problems, iatrogenic injuries because of cast saw, unnoticeable compartment syndrome, wound infection and so on. Team along with faculty from SiB, AIIMS, and IIT-delhi conceptualized and developed a cast named FlexiOH™. We finished early prototyping , concept validation and specification development by end of our internship.