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

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

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

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.