Decreasing cast saw injuries: Developing a novel real-time temperature sensor system for cast saw blades

<b>Introduction:</b> Cast saws may cause burns secondary to generated heat. This study aimed to develop a real-time temperature feedback system to alert users of increasingly unsafe saw blade temperatures. <b>Methods:</b> A sensor device was designed for the Stryker 940 cast saw, measuring temperature at the two blade ends and providing real-time feedback through an LED-light system (green, yellow, red, blinking red) with adjustable temperature ranges. LED ranges were determined using temperature data from four cast technicians. "Skin" touches were assessed with conductivity from the blade to copper strips within cast padding. Users were asked to remove standardized casts, completing three test runs with LED indicators off and three with the light on. Time spent within each temperature range and number of "skin" touches per run were analyzed. <b>Results:</b> With the LED on, the percentage of time spent in the green zone increased (<i>p</i> < .0001) while percentage of time in the red zone decreased (<i>p</i> < .0001) across all test groups. Average time per run increased with the LED on. Although not statistically significant, the number of "skin" touches decreased across all groups with LED on (<i>p</i> = .0630). <b>Conclusions:</b> A temperature-sensitive LED light connection to cast saw blades can potentially decrease user time spent in unsafe temperatures and risk of cast saw burns.