By applying Axiomatic Design, a Smart Medical Cast was developed to provide patients, who are suffering from forearm fractures, with a personalized healing process. The device monitors the overall healing status and three complications, which are: Muscle Atrophy, Compartment Syndrome, and Deep Vein Thrombosis. In the conceptual phase, desk research has been performed to find biomarkers that correlate with the monitored processes. Per biomarker, a measuring principle has been designed and these combined formed the design of the smart medical cast. Following the design phase, two tests were performed on healthy individuals to measure the robustness in a real application. The first test focused on correctly measuring the biomarkers and further specifying the sensor specifications. For the second test, a new prototype was used to determine correlations between the measured data and the monitored process and the impact of application during the casting process. The test results show that the measuring system can measure the biomarkers within the expected range, except for bone density. No significant impact on the casting process was measured. The Smart Medical Cast has only been evaluated in situations without a fracture, the next step will be to test the measurables in an environment with a fracture