Cast Removal Tools

Professional Cast Removal Tools

Removing an orthopedic cast safely requires the right instruments. Whether you're a clinician cutting through fiberglass in a busy orthopedic office or a casting technician working with plaster, OrthoTape carries the full range of professional cast removal tools — from cast cutting saws and cast spreaders to cast shears, orthopedic scissors, and vacuum systems.

What's in This Collection

Cast Cutting Saws

• Stryker 940 Cast Cutting Saw (Refurbished) — Industry-standard oscillating cast saw; rebuilt to OEM specs
• Stryker 840 Cast Cutting Saw – Long Cord (Rebuilt) — Extended cord for clinical flexibility; fully refurbished
• DeSoutter CC7 CleanCast Cast Cutting Saw with Vacuum — Integrated dust collection; ideal for clean, low-debris cast removal
• DeSoutter CC8 Cast Saw with Power Supply — High-performance corded cast saw with included power supply
• American Orthopedic Cast Saw Cutter (Refurbished) — Reliable workhorse saw; professionally rebuilt
• American Orthopedic Cast Saw Cutter Blue (New) — Brand new unit; ready for immediate clinical use

Cast Removal Systems with Vacuum

• Stryker 864 OrthoVac Cast Removal System with 840 Saw (Rebuilt) — Complete cast removal station with integrated vacuum; minimizes cast dust exposure
• American Orthopedic Cast Saw Vacuum Nozzle — Replacement vacuum nozzle for American Orthopedic cast saws

Cast Shears & Scissors

• Orthopedic Cast Removal Casting Shears — Heavy-duty shears designed to cut through fiberglass casting tape without a powered saw
• Fiskars Razor Edge 8" Orthopedic Scissors — Precision scissors for cutting cast padding, stockinette, and soft bandaging

Cast Spreaders

• BSN Medical Stainless Steel Cast Spreader — Bivalves the cast after cutting for safe, controlled removal
• BSN Medical Henning Stainless Steel Cast Spreader — Henning-style spreader for wider cast openings; stainless steel construction

Cast Stands & Patient Protection

• BSN Medical Adjustable Cast Stand — Positions the limb during casting and removal; adjustable height
• Zip Stick Safe Cast Removal Tool — Slides between the cast and skin to protect the patient during saw cutting; reduces anxiety and injury risk

The Complete Cast Removal Process

A proper cast removal typically involves four steps and four tools working together:

1. Cut — A cast saw (oscillating, not rotating) cuts through the fiberglass or plaster shell along both sides of the cast
2. Protect — A Zip Stick or similar guard is slid under the cast to shield the skin from the blade
3. Spread — A cast spreader bivalves the two halves apart
4. Trim — Cast shears and scissors remove the underlying padding and stockinette

Frequently Asked Questions

What is the safest way to remove a fiberglass cast?
The safest method uses an oscillating cast saw (which vibrates rather than rotates, preventing skin cuts), a Zip Stick to protect the skin, a cast spreader to open the shell, and cast shears to cut through the padding. This process should always be performed by a trained clinician.

Can cast shears cut through fiberglass?
Yes — heavy-duty orthopedic cast shears are specifically designed to cut through fiberglass casting tape. They are a quieter, less intimidating alternative to a powered cast saw, particularly useful for pediatric patients.

What is a cast spreader used for?
After the cast is cut along both sides, a cast spreader is inserted into the cut and leveraged open to bivalve (split) the cast into two halves, allowing it to be lifted off the limb without pulling or twisting.

Do you sell refurbished cast saws?
Yes. OrthoTape offers professionally refurbished cast saws from Stryker and American Orthopedic, rebuilt to OEM specifications at a significantly lower cost than new units. All refurbished saws are tested before shipping.

What is the Zip Stick?
The Zip Stick is a thin, flat guard that slides between the cast and the patient's skin before the saw is used. It acts as a barrier to prevent accidental skin contact with the blade, reducing patient anxiety and the risk of superficial cuts during cast removal.