Before Molding Determine Why You Are Using the EXOS Brace

Manufacturer Standard EXOS Oven Heating Method

Enovis/DJO instructions for applicable EXOS upper-extremity products use an EXOS dry-heat oven to make the thermoformable shell pliable before custom molding.

Always review the instructions supplied with your particular EXOS product because fitting details can vary by model.

• Open the new EXOS brace before heating.
• Never heat an EXOS brace while it is being worn.
• The brace should be pliable but not too hot to handle comfortably before application.
• Do not aggressively tighten the BOA® Fit System while the thermoformable shell is still soft.
• Allow the shell to cool and firm before final tightening.

Alternative Home Method Heating an EXOS Brace in a Controlled Water Bath

What You Will Need

• A large heat-safe glass baking or cake dish, preferably 9 × 13 inches or larger, or a similarly sized stainless-steel container
• A microwave-safe glass measuring cup
• A reliable digital food or cooking thermometer
• Water
• Heat-resistant kitchen gloves
• Silicone-tipped kitchen tongs
• Clean absorbent towels
• A timer
• Your EXOS brace

Choose a water-bath dish large and deep enough for the opened thermoformable brace to lie naturally in the water and be fully submerged without sharply folding, bending or forcing the brace into the container.

Step 1 Prepare a Safe Work Area

Place the large water-bath dish on a stable, heat-resistant counter or work surface where it cannot easily be knocked over.

• Keep children and pets away from the work area.
• Keep electrical appliances and cords away from the water.
• Keep the dish away from the edge of the counter.
• Do not perform the molding procedure with the large dish sitting on an active stove burner.
• Use only cookware and measuring containers designed to safely hold hot water.
• Avoid sudden temperature changes that could cause glass cookware to crack.

Step 2 Heat the Water Separately and Add It to the Water Bath

For most home users, the simplest and safer setup is to heat the water separately in a microwave-safe glass measuring cup and then carefully transfer the heated water into the larger water-bath dish.

This avoids trying to lift or remove a large baking dish filled with very hot water from the microwave.

Suggested Microwave Water Heating Method

1. Place the empty large water-bath dish on the stable counter where the molding procedure will be performed.
2. Fill a microwave-safe glass measuring cup with water.
3. Heat the water in controlled microwave intervals rather than relying on one fixed heating time. Microwave wattage and heating speed vary by appliance.
4. Carefully remove the measuring cup using appropriate hand protection.
5. Allow the water to settle briefly and stir it carefully so the temperature is distributed more evenly.
6. Check the water temperature using a reliable digital food thermometer. Do not place a standard food thermometer in the microwave unless its manufacturer specifically states that it is microwave safe.
7. Once the water is within the intended temperature range, carefully pour it into the larger water-bath dish.
8. Repeat with additional measuring cups of heated water until the large dish contains enough water to fully submerge the EXOS brace.
9. Stir the water in the large dish thoroughly and measure the final bath temperature again immediately before adding the brace.

Water transfers heat into the EXOS shell differently and generally more efficiently than dry air. For this reason, the manufacturer's 200°F (93°C) dry-oven setting should not simply be duplicated as the water-bath temperature.

For this alternative home method, OrthoTape recommends not exceeding approximately 180°F (82°C).

Step 3 Prepare the EXOS Brace for Heating

Preparation depends on whether you have a brand-new unmolded EXOS brace or a previously molded EXOS brace that you are reheating to adjust the fit.

Before Heating Either Type

1. Never heat an EXOS brace while it is being worn.
2. Fully loosen the BOA® Fit System, straps, lacing or other closures.
3. Open the brace as fully as its design permits so the thermoformable material can warm evenly.
4. For a new brace, keep it in its open unmolded configuration until it has been heated.
5. For a previously molded brace, note its existing contour before reheating.

Step 4 Fully Submerge and Warm the EXOS Brace

The manufacturer-standard EXOS dry-heat process for applicable upper-extremity models uses approximately 3–4 minutes or until the material becomes pliable.

For this alternative water-bath method, use the EXOS oven time only as a general reference point. Water transfers heat differently than dry air, so monitor the brace closely rather than relying only on the timer.

1. Verify that the final water-bath temperature is within the intended range.
2. Place the opened EXOS brace into the controlled hot-water bath so the thermoformable portion is fully submerged.
3. Make sure the brace has enough room to lie naturally without being sharply folded, compressed or forced into the container.
4. Start the timer once the brace is fully submerged.
5. Use the manufacturer's approximately 3–4 minute dry-oven heating time only as a general benchmark.
6. Because water transfers heat efficiently, begin checking the brace at approximately 2 minutes.
7. After the first check, recheck the thermoformable material approximately every 20–30 seconds.
8. Remove the brace when the material has become uniformly flexible enough to wrap and contour smoothly around the appropriate body part.
9. Do not continue heating solely to reach a particular time.

Step 5 Remove the Brace Let It Cool and Remove Excess Water

1. Carefully remove the warm EXOS brace from the water bath using heat-resistant gloves or appropriate tongs.
2. Allow excess water to drain back into the dish.
3. Use a clean towel to gently remove excess surface water from the inside and outside of the brace. The brace does not need to be completely dry at this point.
4. Most importantly, allow the brace to cool until it is comfortable to touch and can be safely handled with bare hands.
5. Before placing the brace against the skin, carefully check the temperature of several areas of the brace with your hands.
6. Never place an EXOS brace against the skin while it still feels excessively hot.

Step 6 Position the Hand Wrist Thumb or Fingers

Position the body part appropriate to your particular EXOS model. This may include the hand, wrist, forearm, thumb, fingers or another area.

Step 7 Wrap and Mold the Warm EXOS Brace

Once the previously flat EXOS brace is warm and pliable, place it around the appropriate body part and gently shape the thermoformable shell to the individual anatomy.

Use Broad Palm Pressure

Use broad, gentle pressure from the palms of your hands rather than pushing sharply with your fingertips.

Broad pressure helps create a smooth contour and reduces the chance of creating concentrated pressure points.

Depending on the specific EXOS model, pay particular attention around:

• Wrist bones
• Knuckles
• Thumb openings
• Finger areas
• Edges of the brace
• Other prominent bony areas

Step 8 Do Not Fully Tighten the BOA System While the Brace Is Soft

If your EXOS product uses the BOA® Fit System, remove enough cable slack to position the brace correctly.

Do not aggressively tighten the BOA system while the thermoformable material remains soft.

Excessive tension while the material is pliable can create indentations or distort the molded shape.

Step 9 Allow the EXOS Brace to Fully Cool and Harden

Maintain the intended contour while the thermoformable material cools and hardens.

Avoid repeatedly bending or reshaping the brace while it is cooling unless you are intentionally correcting the contour.

Allow the brace to return completely to room temperature and become firm before making the final fit evaluation.

Step 10 Check the Final EXOS Brace Fit

The finished brace should feel supportive and secure without being excessively tight.

Check for:

• Increasing pain
• Numbness
• Tingling
• Burning
• Unusual swelling
• Pale, blue or unusual skin discoloration
• Cold fingers
• Loss of sensation
• Sharp or persistent pressure points
• Skin irritation or breakdown
• Excessive compression
• A brace that remains excessively loose
• Unexpected movement of an injured area

After Molding Remove the Brace and Allow It to Dry Completely

Once the EXOS brace has been fully molded, has returned to room temperature and has become firm in its new custom shape, the initial fitting process is complete.

If your medical instructions allow the brace to be removed, take the newly molded brace back off and allow it to dry completely before beginning normal wear.

1. Remove the fully cooled and hardened brace.
2. Towel-dry any remaining moisture from the inside and outside.
3. Leave the brace open in a well-ventilated area until completely dry.
4. A hair dryer on a high-volume cool-air setting may be used to help dry the inside of the brace.
5. Once the brace and skin are completely dry, put the brace back on and adjust the BOA® Fit System or other closure to the appropriate final fit.

Can an EXOS Brace Be Reheated and Remolded?

Yes. One of the useful characteristics of EXOS thermoformable bracing is that the shape can be adjusted when the fit changes.

For example, an EXOS brace that was custom molded while significant swelling was present may become loose as the swelling decreases.

Remolding may help:

• Take up excess space after swelling decreases
• Improve a loose area
• Smooth an uncomfortable contour
• Improve contact around the hand, wrist or forearm
• Correct a minor fit issue

If the brace is being used for a fracture, surgery or significant active injury, substantial remolding should remain under the direction of the healthcare provider managing the condition.

Can You Use a Hair Dryer With an EXOS Brace?

Enovis patient-care guidance recommends a hair dryer on a high-volume cool setting to help thoroughly dry the inside of the EXOS brace and the skin after approved water exposure.

For substantial thermoforming or reshaping, use a controlled heating method rather than an uncontrolled concentrated heat source.

Do not use an industrial heat gun, open flame or other extreme localized heat source on an EXOS brace.

EXOS Brace Heating Fitting and Remolding FAQs

EXOS product-use information reviewed August 2026.