Exos Cast & Removable Cast Brace — Wrist, Thumb, Boxer's Fracture

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Exos Cast — Thermoformable Removable Cast for Wrist, Hand & Thumb Fractures

The Exos Cast by DJO Global is a thermoformable removable cast that combines the superior support of traditional casting with the convenience, comfort, and adjustability of modern orthotic design. Also called an Exos brace or Exos removable cast, it is custom-molded directly to the patient's anatomy using heat, creating a perfect fit that is waterproof, lightweight, radiolucent (X-ray friendly), and fully adjustable throughout treatment. OrthoTape carries the complete Exos Cast line including wrist fracture braces, short arm braces, thumb spica braces, and boxer's fracture braces — all featuring the BOA Fit System for micro-adjustable precision support.

What Makes the Exos Cast Different?

Exos Cast uses advanced thermoformable plastic that becomes pliable when heated to 200°F (93°C), allowing healthcare providers to mold the cast directly to the patient's anatomy for a custom fit. Once cooled, the material hardens into a rigid, supportive structure that immobilizes the injury while remaining lightweight and comfortable. This is why many clinicians refer to it as an Exos cast — it delivers cast-level immobilization in a removable, adjustable format.

Key Advantages Over Traditional Casts

Reformable throughout treatment — can be reheated and remolded as swelling changes, eliminating multiple cast changes
Fully waterproof — patients can shower, bathe, and swim; antimicrobial-treated material is hand-washable
Radiolucent — X-rays pass through without removing the cast, saving time and maintaining continuous immobilization
Lightweight & low-profile — significantly lighter than plaster; fits under clothing and sleeves
Micro-adjustable BOA Fit System — turn the dial to tighten, press to release; accommodates swelling fluctuations throughout the day
Lockable for compliance — optional BOA Locking Ring prevents unauthorized removal; ideal for pediatric patients

Exos Cast Product Line

Exos Wrist Fracture Brace with BOA — Comprehensive wrist immobilization for stable distal radius fractures, distal ulna styloid fractures, carpal bone injuries, scapholunate dislocations, TFCC tears, and wrist sprains. Openings at the thenar eminence and palmar crease allow functional hand use. Available XXS–XL.

Exos Short Arm Fracture Brace with Open Thumb — Wrist and forearm immobilization with the thumb free for functional grip. Indicated for distal radius fractures (Colles', Smith's), distal ulna fractures, and post-operative wrist stabilization. Available in adult and pediatric sizes.

Exos Thumb Spica Fracture Brace — Immobilizes the thumb MCP and CMC joints with secondary wrist support. Indicated for scaphoid fractures, thumb fractures, first metacarpal fractures, CMC arthritis, gamekeeper's thumb (UCL injury), and DeQuervain's tenosynovitis. Short and Long Thumb Spica II versions available.

Exos Boxer's Fracture Brace — Ulnar gutter design for 4th and 5th metacarpal fractures. Achieves greater than 70° of MCP flexion for optimal healing position. Adjustable straps across web space and around 4th/5th digits; trimmable finger section for desired range of motion.

Exos Cast vs. Traditional Cast

Feature	Exos Cast (Removable)	Traditional Cast
Waterproof	✓ Fully waterproof, can shower/swim	✗ Ruined if wet
Adjustable	✓ Micro-adjustable BOA system	✗ Fixed, cannot adjust
Removable	✓ Removable; lockable for compliance	✗ Requires clinical removal
Reformable	✓ Reheat and remold as needed	✗ Must replace entirely
X-Ray	✓ Radiolucent, no removal needed	✗ Must remove for X-rays
Weight	✓ Lightweight	✗ Heavy (especially plaster)
Hygiene	✓ Washable, antimicrobial	✗ Develops odor, cannot clean
Skin Access	✓ Can inspect skin regularly	✗ Skin hidden until removal

How the Exos Cast Is Applied

Step 1 — Heat: Heat the Exos Cast in an Exos oven at 200°F (93°C) for approximately 3–4 minutes until pliable.
Step 2 — Apply: Ensure skin is completely dry. Fit the cast on the patient's extremity in the desired position. Remove slack in the BOA lace by turning the knob — do NOT fully tighten until cooled.
Step 3 — Mold: While warm and pliable, mold the cast to the exact contours of the patient's anatomy. Apply gentle pressure around bony prominences and soft tissue.
Step 4 — Cool & Adjust: Allow to cool and harden (~5–10 minutes). Once fully hardened, tighten the BOA knob to desired tension. Attach optional BOA Locking Ring if needed.

The Exos Cast must be applied by qualified orthopedic technicians, physicians, or trained casting staff. Improper application can result in inadequate immobilization or skin complications.

Frequently Asked Questions — Exos Cast

Is the Exos Cast considered a removable cast?

Yes — many clinicians and patients refer to the Exos as a removable cast because it provides rigid, cast-equivalent immobilization while remaining removable and adjustable. The optional BOA Locking Ring can restrict removal for compliance when needed, making it functionally equivalent to a traditional cast for less compliant patients.

Can I shower and swim with an Exos Cast?

Yes. The Exos Cast is fully waterproof. You can shower, bathe, and swim without covering or removing it. Hand-wash with mild soap and air-dry or use a hairdryer to maintain hygiene — a major advantage over traditional fiberglass or plaster casts.

Can I get X-rays with the Exos Cast on?

Yes. The Exos Cast is radiolucent, meaning X-rays pass through the material for clear bone visualization without removing the cast. This saves time at follow-up appointments and ensures continuous immobilization throughout the imaging process.

What if the Exos Cast becomes too loose as swelling decreases?

Simply tighten the BOA dial for a snugger fit. If significant looseness persists, the cast can be reheated and remolded by your healthcare provider for a better fit — no need for a completely new cast. This is a major cost and convenience advantage over traditional casting.

Is the Exos Cast as strong as a traditional cast?

Yes. When properly molded by a trained clinician, the Exos Cast provides equivalent immobilization to traditional fiberglass casts for stable fractures. It is not indicated for unstable or severely displaced fractures requiring surgical fixation.

Is the Exos Cast FSA or HSA eligible?

Yes. The Exos Cast is a medical device and is generally FSA and HSA eligible when prescribed by a physician. It may also qualify for insurance reimbursement as durable medical equipment (DME). Contact OrthoTape for HCPCS documentation. A prescription may be required by your plan for reimbursement.

Related Collections
Wrist Sprain & Fracture Braces — full wrist brace collection including splints and supports.
Casting Supplies — fiberglass tape, padding, stockinette, and cast kits.
All Bracing & Support — knee, back, shoulder, ankle, and foot braces.

Authorized Dealer: OrthoTape is an authorized dealer of DJO Global Exos products. All Exos Cast braces are covered by the 8-week manufacturer's warranty covering defects in workmanship and materials. FSA/HSA eligible — contact us for HCPCS documentation. The Exos Cast must be applied by qualified orthopedic technicians, physicians, or trained casting staff. Not indicated for unstable fractures or injuries requiring surgical intervention. Always follow your physician's guidance. This content is for informational purposes only and does not constitute medical advice.