New Cairo Technological University
Faculty of Applied Health Sciences Technology
Graduation Project · 2026
Bio-Neck
Dynamic Cervical Orthosis
A custom, adjustable orthosis for paediatric post-burn neck scar contracture — combining sustained therapeutic stretch with preserved, functional neck motion.
Department
Prosthetics & Orthotics
Presentation Contents
Eight parts, one device
01The Clinical Problem
Why post-burn neck contracture matters
02The Bio-Neck Device
Components and design principles
03Mechanism & Biomechanics
How controlled force remodels scar
04Challenges & Future Direction
Honest limitations and next steps
05Market & Opportunity
Who needs it and how many
06Competitive Landscape
Dynamic vs static, and the gap
07Business Case & Financials
Unit economics and profitability
08Conclusion
Why Bio-Neck is worth building
01
The Clinical Problem
When the neck heals after a severe burn, the skin shrinks — and in children that process is relentless, disfiguring, and largely preventable.
Section 01 · The Problem
Post-burn neck scar contracture
As burned skin heals, it naturally shrinks. In paediatric patients this shrinkage is aggressive — and rapid growth keeps making it worse.
→Tissue shrinkage pulls the chin down toward the chest.
→Rapid growth exacerbates the risk of permanent deformity.
→Severe cases require complex, painful corrective surgery.
The patients are children aged 3–15 who need long-term cervical support and scar management.
Section 01 · The Problem
Paediatric anatomical constraints
01
Tissue shrinkage
Scar contraction pulls the chin toward the chest.
02
Loss of mobility
Fixed bracing blocks the stretch that healing tissue needs.
03
Paediatric impact
Rapid growth magnifies the risk of permanent deformity.
04
Permanent stiffness
Standard collars lock the neck, causing joint atrophy.
05
Surgical reliance
Severe deformity often means repeated corrective surgery.
Section 01 · The Problem
The current standard of care
Existing solutions either immobilise the neck or are improvised at the bedside. Neither delivers the sustained, adjustable stretch that scar remodelling requires.
Soft & rigid collars — general-purpose, not pediatric-specific.
Improvised gauze collars — no controlled force, no scar remodelling.
Custom thermoplastic splints — expensive and static.
An improvised cloth collar — the reality of care where no purpose-built paediatric orthosis exists.
Section 01 · The Problem
A large, underserved population
100k+
children hospitalised for burns each year in the US alone.
10–15%
go on to develop neck contractures requiring intervention.
Higher
prevalence still in low- and middle-income countries with limited acute care.
Thousands of new candidates appear every year — a substantial cohort concentrated in burn centres, children's hospitals, and rehabilitation units, and currently lacking an effective, scalable solution.
Section 01 · The Problem
The cost to the system
Without intervention
Recurring, relentless expenditure
Repeated contracture-release surgeries
Inpatient stays & infection management
Revision skin grafting
Lost parental productivity & lifelong disability support
⟶
With an orthosis
A single, predictable device cost
$100Ms
in system-level savings over a decade — simply by preventing recurrence, before indirect costs are even counted.
02
The Bio-Neck Device
A two-platform orthosis that anchors on the chest and drives adjustable distraction at the chin — correcting in three planes while letting the neck move.
Section 02 · The Device
Product overview
A fixed chest base anchors the device; a movement platform above carries the chin support and sliding frame.
Central screw — vertical distraction (up / down)
Lateral screws — left / right asymmetry control
High-density foam — safe pressure distribution
Section 02 · The Device
Component explorer
▸ click a component
{{ explorer }}
Section 02 · The Device
Designed around six principles
Every requirement comes directly from what clinicians and parents asked for.
Comfort first
Soft, breathable contact surfaces for long wearing periods.
Adjustable to growth
Screw-driven length changes adapt as the child grows.
Lightweight
Aluminium frame keeps the structure light on small bodies.
Easy to wear
Velcro straps and buckle for quick donning and removal.
Child-friendly
An approachable look that improves paediatric compliance.
Affordable
A unit cost low enough for routine clinical procurement.
03
Mechanism & Biomechanics
Because it is molded to the patient's anatomy, the orthosis applies more accurate corrective force — and better pressure distribution — than any prefabricated device.
Section 03 · Mechanism
Low-load prolonged stretch
The orthosis applies a controlled external force over long periods. Gentle and continuous, it does what brief, forceful stretching cannot.
+Gradual elongation of scar tissue
+Increased tissue extensibility
+Reduced stiffness and fibrotic banding
The goal
Prevent scar shortening — and restore neck extension and mobility.
Section 03 · Mechanism
Five therapeutic mechanisms
01
Sustained positioning
Holds the neck in corrected extension, opposing flexion contraction.
02
Prolonged stretch
Continuous gentle force elongates scar and reduces stiffness.
03
Collagen remodelling
Aligns fibres along the stress line for more functional scar.
04
Myofibroblast counter-force
Resists the contractile forces that drive progressive deformity.
05
Pressure & scar control
Even pressure flattens raised scar and reduces vascularity.
Section 03 · Biomechanics
The three-point pressure system
Three balanced forces hold a slight hyperextension that resists the pull of contraction.
Point 1 · Fixed base
Chest support
Supports the axial reaction force of the traction generated by the upper assembly.
Point 2 · Anterior force
Chin support
Exerts a force opposing the torque that pulls the chin toward the chest.
Point 3 · Posterior force
Occipital support
Rests on the base of the skull, providing the reaction force that controls hyperextension.
Section 03 · Biomechanics
Continuous axial tension & tissue remodelling
Anterior scars contract continuously, creating a torque that pulls the chin and jaw toward the chest. The central vertical screw answers with a continuous axial distraction force.
Mechanical creep plus biological remodelling prompt fibroblasts to align collagen along the line of stress — rather than the random, interwoven matrix that drives recurrence.
Distraction
↑
Scar elongates along the stress line
↓
Contraction force
Section 03 · Biomechanics
Correcting asymmetry
Scar tissue rarely contracts evenly — so a torticollis-like deformity can develop. Independent lateral screws answer it.
The problem
Asymmetric lateral moment
Uneven contraction twists the neck into an abnormal, off-axis posture.
The adjustment
Independent left & right screws
L ⟷ REach side's length is altered independently on the sliding frame.
Correction is achieved by generating an anti-torque that rebalances the deviation back to neutral.
Section 03 · Biomechanics
Surface stress distribution
Burned skin lacks elasticity and blood supply, so continuous force must be spread carefully. The engineering principle is simple:
›Wide chin, occipital and chest supports lined with dense foam.
›Larger surface area lowers the local pressure for the same force.
›Pressure is held below the critical capillary threshold.
Governing equation
Stress = F⁄A
< 32 mmHg
held below capillary closing pressure
Section 03 · Biomechanics
Planes of correction
Sagittal — flexion / extension
Chin support + central screw prevent the chin dropping back to the chest.
Frontal — lateral flexion
Lateral screws correct head tilt from uneven scar.
Transverse — rotation
The sliding frame lets the skull turn so the joints don't stiffen.
Section 03 · Biomechanics
Controlled motion in three planes
Unlike a static collar, Bio-Neck corrects while letting the neck move.
Sagittal
Flexion · Extension
Chin support & central screw
Frontal
Lateral flexion
Left & right lateral screws
Transverse
Rotation
Sliding frame
04
Challenges & Future Direction
A dynamic orthosis is powerful but demanding. Acknowledging its limits is how we make it clinically credible.
Section 04 · Challenges
Challenges & limitations
Skin breakdown
Continuous pressure can irritate fragile burned skin.
Pain & discomfort
Scar sensitivity and tension can reduce compliance.
Difficult fit
Edema and scar maturation demand frequent refitting.
Limited compliance
Bulk, heat and appearance discourage consistent wear.
Activity restriction
May interfere with eating, speaking, sleeping and hygiene.
Progression risk
Severe burns may keep contracting despite treatment.
Continuous monitoring
Regular follow-up is essential throughout healing.
Every limitation is a design brief for the next iteration.
Section 04 · Future Direction
Future research directions
01Lightweight, breathable materials to reduce irritation and improve comfort during prolonged wear.
02Sensor integration monitoring neck position, wear time and pressure points.
03Cosmetic design — better aesthetics to support compliance and psychological comfort.
04Long-term clinical trials on contracture prevention, range of motion and quality of life.
05Integrated programs uniting orthotics, exercise, scar management and patient education.
06Interdisciplinary collaboration across therapists, burn surgeons and rehab teams.
05
Market & Opportunity
A custom-made cervical orthosis for paediatric neck scar contracture — a defined clinical population that current products do not serve well.
Section 05 · Market
Target market
The main users are children aged 3–15 who need long-term cervical support and scar management — reached through institutional buyers.
Paediatric rehab centres
Hospital burn units
Orthotic & prosthetic clinics
Physical therapy centres
3–15
years old
The age window where growth makes early intervention most valuable.
Section 05 · Market
Market need & customer requirements
The problem with today's devices
Poor comfort over long wear periods
Limited adjustability for growing children
Skin irritation and pressure points
Unattractive look → low compliance
What customers want
Soft, breathable materials
Adjustable to growth
Lightweight structure
Easy to wear & remove
Child-friendly appearance
Affordable cost
Section 05 · Market
Market size & demand
High prevalence
Burns and post-surgical contractures are common in paediatric patients, especially in developing countries.
Unmet institutional need
Hospitals and rehab centres require affordable, customised orthotic solutions that don't yet exist.
Rising awareness
Growing recognition of early intervention and rehabilitation keeps expanding the market.
Section 05 · Market
Existing products & the gap
On the market today
Soft cervical collars
Philadelphia collars
Thermoplastic neck orthoses
General-purpose · expensive when customised · not optimised for scar contracture.
The market gap
Existing devices immobilise and position. None deliver dynamic scar management.
Burn patients need both contracture prevention and preserved functional neck movement — an opening for an improved custom solution.
06
Competitive Landscape
A dynamic orthosis is a specialised, highly effective solution — and understanding its trade-offs is what makes the case defensible.
Section 06 · Competition
Dynamic vs static orthosis
Factor
Dynamic orthosis
Static orthosis
Contracture management
Continuous graded stretching
Maintains position only
Mobility improvement
Supports cervical ROM gains
Limited effect
Comfort
Moving parts add bulk
Simpler, more comfortable
Cost
Higher — custom fabrication
Lower cost
Follow-up
Frequent adjustments
Fewer adjustments
Section 06 · Competition
Strengths & limitations of dynamic orthoses
Key strengths
Continuous low-load stretching
Remodels scar tissue gradually.
Improved neck mobility
Supports progressive range-of-motion gains.
Better contracture prevention
More effective than static positioning alone.
Key limitations
Higher cost
Custom fabrication and specialised parts.
Complex fitting
Skilled clinicians and repeated adjustments.
Comfort & skin-irritation risk
Bulk and pressure on fragile burned tissue.
Section 06 · Competition
Industry landscape
Established manufacturers focus on orthopaedic trauma, spinal stabilisation and post-surgical rehab — not burn care.
Össur
Aspen
DeRoyal
Thuasne
Medline
Market gap
Current orthoses focus on immobilisation and positioning — leaving dynamic burn-scar management unaddressed.
Section 06 · Competition
SWOT analysis
Strengths
Low-load stretching promotes scar remodelling · improved cervical ROM · supports functional movement and reduces disuse.
Weaknesses
Higher manufacturing & fitting cost · requires specialised clinical expertise · increased risk of skin irritation.
Opportunities
Growing demand for personalised rehabilitation · adoption of digital design and fabrication.
Threats
Low-cost static collars · therapist-fabricated splints · limited reimbursement pathways.
Section 06 · Competition
Strategic competitive advantage
Immobilisation
static collars
Bio-Neck
therapeutic stretch + preserved function
Free mobility
no correction
A unique balance: adjustable dynamic stretching, improved comfort, adaptability during recovery, better compliance, and reduced severity of neck contractures.
07
Business Case & Financials
A first-year plan: 250 units, profitable from month one, with healthy margins on a justified premium device.
Section 07 · Financials
Year-one financial snapshot
Net profit after tax
$20,251
Break-even sits at just 14 units per month — reached from the very first month of production.
Section 07 · Financials
Bill of materials — per unit
Original components
Aluminium frame · chin · chest supports$11.50
Sliding mechanism$16.00
Adjustment knob · straps · screws & nuts$5.00
New components — the upgrade
Left / right lateral screws (×2)$9.00
Central screw — up / down (×1)$6.00
Ball joint connectors (×2)$6.00
High-density medical foam$8.00
Total COGS per unit
$61.50
Sells at $350 per unit
≈ 82% gross margin
Section 07 · Financials
Graduated production ramp
Output climbs from 10 units to a steady ≈23 / month — 250 units across the year.
{{ unitsChart }}
Section 07 · Financials
Cumulative cash flow
Negative for a single month, then a steady climb to $24,125 by December.
{{ cashChart }}
Section 07 · Financials
Income statement — annual
Total sales revenue (250 × $350)$87,500
Cost of goods sold (250 × $61.50)−$15,375
Technician salary ($2,800 × 12)−$33,600
Workshop rent ($900 × 12)−$10,800
Utilities & insurance ($300 × 12)−$3,600
EBITDA$24,125
Depreciation & taxes (15%)−$3,874
Net profit after tax
$20,251
Profitable in year one — on a single technician and one workshop.
Section 07 · Financials
Market strategy
Value
Controlled, adjustable stretch
Prevents and reduces post-burn contractures with better comfort and compliance.
Pricing
Affordable premium
A justified price point that stays cost-effective to manufacture.
Distribution
Institutional B2B
Hospitals, burn units, rehab centres, orthotic clinics and medical suppliers.
Promotion
Reach clinicians
Conferences, workshops, educational brochures and published clinical outcomes.
Section 08 · Conclusion
A device worth building
Bio-Neck addresses an important clinical and market need by combining comfort, functionality, affordability, and customisation — for a population current products do not serve.
Clinical
Dynamic stretch with preserved motion.
Engineering
Three-plane correction, safe pressure.
Market
A defined, underserved population.
Business
Profitable from year one.
New Cairo Technological University
Faculty of Applied Health Sciences Technology
Thank you
We welcome your questions.
Project
Bio-Neck Dynamic Orthosis
Department
Prosthetics & Orthotics
