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EXOS Brace Fitting Guide How to Heat Mold and Remold an EXOS Cast Brace
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OrthoTape EXOS Fitting and Remolding Guide
EXOS Brace Fitting Guide How to Heat Mold and Remold an EXOS Brace
EXOS is different from a conventional ready-to-wear brace. A new EXOS brace is supplied in an open, relatively flat and unmolded configuration. The thermoformable shell is designed to be heated first, molded around the individual wearer and then allowed to cool into a firm custom fit.
Your New EXOS Brace May Arrive Flat This Is Normal
EXOS is not a conventional pre-shaped ready-to-wear brace. A brand-new EXOS product may arrive relatively flat, open or pancake-like because it has not yet been custom molded.
The thermoformable shell is designed to be heated first and then molded around the appropriate anatomy. Depending on the EXOS model, this may include the wrist, hand, forearm, thumb, fingers or a combination of these areas.
Once the heated material is shaped around the wearer and allowed to cool, it becomes firm again and retains its custom contour.
Do not assume that the brace is the wrong shape or does not fit simply because it looks flat before heating. Thermoforming is an intended part of fitting a new EXOS brace.
Quick Answer How Is an EXOS Brace Custom Fitted?
A new EXOS brace is heated until the thermoformable material becomes pliable. The warm brace is then wrapped and molded around the appropriate area of the body and held in the desired contour while it cools and becomes firm.
New EXOS brace: heat first, then place it around the body and custom mold it.
Previously molded EXOS brace: remove it from the body before reheating, then carefully remold it as needed.
Controlled water bath: alternative OrthoTape home method when an EXOS oven is unavailable. This is not an Enovis-published water-bath protocol.
Fracture, surgery or significant injury: fitting and significant remolding should be performed under the direction of the healthcare professional managing the injury.
General support or protective use: home fitting or minor refitting may be practical when there is no fracture, post-surgical condition or physician-directed immobilization requirement.
Before Heating Confirm the Correct EXOS Model Side and Size
Do not apply heat until you are certain that you received the correct EXOS product, side and size.
Once an EXOS brace has been heated, molded, remolded, worn or otherwise altered, it is no longer eligible for return to OrthoTape. If you are unsure about the product you received, contact OrthoTape before beginning the heating process.
Before Molding Determine Why You Are Using the EXOS Brace
Fracture Surgery or Active Injury
If your EXOS brace is being used for a fracture, suspected fracture, post-surgical condition or significant active injury, fitting and significant remolding should be performed under the direction of your physician, orthopedic provider or other qualified healthcare professional.
Heating and molding the thermoformable material is the mechanical part of the process. Determining the proper anatomical position, alignment and amount of immobilization is the medical part.
OrthoTape strongly recommends having the final fit checked by the healthcare professional managing your injury.
General Support or Protective Use
When an EXOS product is being used for general support or protective use and there is no fracture, post-surgical condition or physician-directed immobilization requirement, home fitting or minor refitting may be a practical option.
The objective is to create a comfortable, supportive custom contour without excessive tightness, pressure points or unnecessary distortion of the brace.
Fracture Warning Do Not Reposition an Injury Yourself
Never use the molding process to straighten, reduce, manipulate or change the position of a fracture.
Keep the injured wrist, hand, thumb, finger, forearm or other body part in the position prescribed by your healthcare provider.
If your doctor has instructed you not to remove a previously fitted brace, do not remove it for reheating or remolding unless your doctor specifically tells you it is safe to do so.
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.
Oven Temperature
200°F
93°C
Typical Heating Time
3–4 Minutes
or until pliable
Never Exceed
212°F
100°C
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.
Why does EXOS require heating? Controlled heat temporarily makes the thermoformable shell flexible. The warm material can then be shaped around the individual anatomy. As it cools, the brace becomes rigid again and retains the custom-molded contour.
Alternative Home Method Heating an EXOS Brace in a Controlled Water Bath
Important This Is Not the Manufacturer Standard EXOS Heating Method
Enovis specifies an EXOS dry-heat heating system for standard thermoforming.
The controlled hot-water method below is an alternative OrthoTape home technique for users who do not have access to an EXOS oven. It is not an Enovis-published or Enovis-validated water-bath fitting protocol and is performed at the user's own risk.
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.
Burn Warning: Water at the temperatures used in this process can cause serious burns. Avoid direct contact with the hot water and use appropriate heat-resistant handling tools.
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.
A practical home method is to heat smaller amounts of water in a microwave-safe glass measuring cup and carefully pour the heated water into the larger heat-safe water-bath dish.
Suggested Microwave Water Heating Method
Place the empty large water-bath dish on the stable counter where the molding procedure will be performed.
Fill a microwave-safe glass measuring cup with water.
Heat the water in controlled microwave intervals rather than relying on one fixed heating time. Microwave wattage and heating speed vary by appliance.
Carefully remove the measuring cup using appropriate hand protection.
Allow the water to settle briefly and stir it carefully so the temperature is distributed more evenly.
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.
Once the water is within the intended temperature range, carefully pour it into the larger water-bath dish.
Repeat with additional measuring cups of heated water until the large dish contains enough water to fully submerge the EXOS brace.
Stir the water in the large dish thoroughly and measure the final bath temperature again immediately before adding the brace.
OrthoTape Suggested Starting Water Temperature
160°F–170°F
approximately 71°C–77°C
This is an OrthoTape alternative starting range for the home water-bath method and is not an Enovis-published water-bath specification.
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).
What If the Water Gets Too Hot?
Do not put the EXOS brace into water that is above the intended water-bath temperature range.
If the water becomes too hot, allow it to cool naturally before proceeding.
If needed, a small amount of cooler water can be added to the large dish. Stir the bath thoroughly afterward so the temperature is evenly distributed.
Always check the water temperature again with the thermometer after adding cooler water or allowing the bath to cool. Do not estimate the temperature by touch.
Microwave Hot Water Safety
Water heated in a microwave can become extremely hot and, in some circumstances, may become superheated and suddenly erupt when the container is moved or the water is disturbed.
Avoid excessive microwave heating, use only microwave-safe containers, follow the microwave manufacturer's instructions and handle heated water carefully. If the water is near boiling or appears excessively hot, allow it to cool before moving or using it.
Have the water bath, thermometer, towel and heat-resistant handling tools ready before heating the EXOS brace.
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.
Brand New EXOS Brace
A new EXOS brace is supplied in an unmolded, relatively flat or open configuration. This is normal.
Do not try to put the rigid flat brace on and judge its final fit before heating it.
The brace is heated first. Once it becomes pliable, it is placed around the appropriate body part and molded to the individual wearer.
Previously Molded EXOS Brace
If the EXOS brace was previously heated and fitted by a doctor, clinic or other healthcare professional and you are reheating it because the fit has changed, remove the brace from the body before applying any heat.
Observe the existing molded contour before reheating so you can preserve its general shape and medically prescribed position unless your healthcare provider has instructed otherwise.
Before Heating Either Type
Never heat an EXOS brace while it is being worn.
Fully loosen the BOA® Fit System, straps, lacing or other closures.
Open the brace as fully as its design permits so the thermoformable material can warm evenly.
For a new brace, keep it in its open unmolded configuration until it has been heated.
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.
Verify that the final water-bath temperature is within the intended range.
Place the opened EXOS brace into the controlled hot-water bath so the thermoformable portion is fully submerged.
Make sure the brace has enough room to lie naturally without being sharply folded, compressed or forced into the container.
Start the timer once the brace is fully submerged.
Use the manufacturer's approximately 3–4 minute dry-oven heating time only as a general benchmark.
Because water transfers heat efficiently, begin checking the brace at approximately 2 minutes.
After the first check, recheck the thermoformable material approximately every 20–30 seconds.
Remove the brace when the material has become uniformly flexible enough to wrap and contour smoothly around the appropriate body part.
Do not continue heating solely to reach a particular time.
The goal is pliability, not maximum temperature or maximum soak time. Once the thermoformable shell is flexible enough to mold smoothly, additional heating is unnecessary.
Use a dish large enough for the open EXOS brace to be fully submerged without folding or forcing the brace into the container.
Step 5 Remove the Brace Let It Cool and Remove Excess Water
Carefully remove the warm EXOS brace from the water bath using heat-resistant gloves or appropriate tongs.
Allow excess water to drain back into the dish.
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.
Most importantly, allow the brace to cool until it is comfortable to touch and can be safely handled with bare hands.
Before placing the brace against the skin, carefully check the temperature of several areas of the brace with your hands.
Never place an EXOS brace against the skin while it still feels excessively hot.
Important: At this stage, the goal is only to remove excess water and make sure the brace is cool enough to safely touch the skin. Do not spend unnecessary time trying to completely dry the brace before molding because the thermoformable material needs to remain warm and pliable while the custom fit is created.
After removing the EXOS brace from the water bath, drain and towel away excess water. Allow the brace to cool until it is comfortable to touch before beginning the molding process.
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.
If the EXOS brace is treating a fracture, surgery or significant injury: use only the position directed by the healthcare professional managing the injury. Do not attempt to use the softened brace to straighten, reduce or reposition injured anatomy.
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.
Remove the fully cooled and hardened brace.
Towel-dry any remaining moisture from the inside and outside.
Leave the brace open in a well-ventilated area until completely dry.
A hair dryer on a high-volume cool-air setting may be used to help dry the inside of the brace.
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.
Why dry it after molding? Immediately after the water bath, the priority is to preserve the limited time while the thermoformable material remains pliable. Once the brace has been molded and has hardened into its new shape, it can be removed and thoroughly dried before normal wear.
Fracture or post-surgical patients: If your physician has instructed you not to remove the EXOS brace, follow your physician's instructions instead. Do not remove a fracture or post-surgical brace solely for drying unless your healthcare provider has told you that removal is permitted.
Using EXOS for a Fracture Have Your Doctor Check the Fit
A comfortable brace is not necessarily a correctly positioned fracture brace.
If your EXOS brace is being used for a fracture, post-surgical condition or significant injury, OrthoTape strongly recommends having the newly molded or remolded fit evaluated by the healthcare professional managing your care.
Your healthcare provider can evaluate alignment, immobilization, pressure, circulation, swelling and whether additional examination or imaging is appropriate.
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.
Stop and Contact Your Healthcare Provider If You Experience
Increasing or severe pain
New or worsening swelling
Numbness or tingling
Loss of sensation
Pale, blue or unusually discolored fingers
Cold fingers
Significant or persistent pressure points
Skin breakdown or persistent irritation
A noticeable change in the position of an injured area
A brace that no longer appears to provide adequate immobilization
Confirm the Product Before Applying Heat
A flat or open appearance is normal for a new unmolded EXOS brace and does not by itself indicate that the product is defective or the wrong shape.
Confirm the correct EXOS model, side and size before beginning the heating and molding process.
Once an EXOS brace has been heated, molded, remolded, worn or otherwise altered, it is no longer eligible for return to OrthoTape.
Shop Authentic EXOS Thermoformable Braces
OrthoTape carries EXOS thermoformable wrist, short-arm, thumb-spica, radial-gutter, boxer's-fracture and other custom-molded brace options.
A new EXOS brace is supplied in an open, relatively flat and unmolded configuration because it is designed to be heated and custom molded to the individual wearer. The flat shape before heating is normal.
Should I try on a new EXOS brace before heating it?
A new rigid EXOS brace is not intended to have its final custom fit before thermoforming. Confirm the correct model, side and size before heating, but the brace is heated first and then molded around the appropriate anatomy.
What temperature does the manufacturer use to heat an EXOS brace?
Enovis instructions for applicable EXOS upper-extremity models specify approximately 200°F (93°C) using the appropriate EXOS dry-heat heating system, generally for approximately 3–4 minutes or until the brace becomes pliable. EXOS products should not be heated above 212°F (100°C). Follow the instructions supplied with the specific EXOS model.
Can an EXOS brace be heated in a hot water bath?
The manufacturer-standard thermoforming method uses an EXOS dry-heat heating system. The controlled water-bath method described on this page is an alternative OrthoTape home technique and is not an Enovis-published or validated EXOS water-bath protocol.
What is the easiest way to heat water for the EXOS water bath?
A practical home method is to heat water separately in a microwave-safe glass measuring cup, carefully transfer it into the larger water-bath dish and repeat until there is enough water for full submersion. Stir the final bath and verify the temperature with a digital thermometer before adding the brace.
What should I do if the water gets too hot?
Do not put the EXOS brace into water that is above the intended temperature range. Allow the water to cool, or carefully add some cooler water if needed. Stir thoroughly and measure the final temperature again before adding the brace.
Does the EXOS brace need to be completely dry before molding?
No. After removing the brace from the water bath, drain and towel away excess water and allow the brace to cool until it is comfortable to touch. The priority is to mold the brace while the thermoformable material is still pliable. Once the brace has been molded, cooled and hardened, remove it if medically permitted and allow it to dry completely before normal wear.
How long should the EXOS brace stay in the alternative water bath?
Use the manufacturer's approximately 3–4 minute EXOS dry-heat time only as a general reference. Because water transfers heat differently from dry air, begin checking the brace at approximately 2 minutes and then every 20–30 seconds. Remove the brace as soon as the thermoformable material becomes uniformly pliable enough to mold.
Should the EXOS brace be fully submerged in the water bath?
For the alternative OrthoTape water-bath method described here, use a container large enough for the opened thermoformable brace to be fully submerged without sharply folding, compressing or forcing the brace into the container.
Can an EXOS brace be reheated when swelling goes down?
The thermoformable EXOS shell can be reshaped when fit requirements change. This can be useful when swelling decreases and a previously well-fitting brace becomes loose. For fracture or post-surgical treatment, significant remolding should be directed and checked by the treating healthcare provider.
Should my doctor check my EXOS fracture brace after it is molded?
Yes. When EXOS is being used for a fracture, post-surgical condition or significant injury, OrthoTape strongly recommends having the final molded or remolded fit checked by the healthcare professional managing the care. Comfort alone does not confirm correct fracture positioning or immobilization.
Can I return an EXOS brace after heating or molding it?
No. Confirm the correct EXOS model, side and size before applying heat. Once the product has been heated, molded, remolded, worn or otherwise altered, it is no longer eligible for return to OrthoTape.
Questions Before Heating Your EXOS Brace?
If you are unsure about the EXOS model, side or size you received, contact OrthoTape before heating or molding the product.
OrthoTape Customer Support help@orthotape.com (800) 580-9887
EXOS product-use information reviewed August 2026.
Medical and safety disclaimer: This page is provided for general product-use education and does not replace diagnosis, professional medical fitting, fracture reduction, imaging, medical treatment or instructions from your physician or orthopedic provider. EXOS products used for fractures, post-surgical conditions or significant injuries should be fitted and used under appropriate medical supervision.
The controlled hot-water technique described on this page is an alternative OrthoTape home method and is not presented as the manufacturer-standard or manufacturer-validated EXOS thermoforming procedure. Enovis specifies dry-heat equipment as its standard thermoforming method.
Improper heating, molding, positioning or use may damage the product or cause burns, pressure injury, impaired circulation, inadequate immobilization or other injury. Stop use and contact a healthcare professional for increasing pain, unusual swelling, numbness, tingling, discoloration, cold fingers, skin breakdown or concern that an injury has changed position.
Not only can you swim and sweat, but its less itchy!
My son was devistated to break his arm and not be able to go swimming over the summer. But once he was switched from a long cast to a short cast and the doctor said he could have a waterproof one, we were ready with this product. Not only did it save our summer by allowing him to swim, he was also able to clean his cast out in the bath after an especially hot and sweaty soccer practice. However, drying the cast out is a pain in the butt.
But most importantly to me, he complained about being itchy far less and his skin looked completely clean and normal once the cast was removed, other than being pale. When his non-waterproof long cast was removed he had a nasty rash that wasnt medically concerning but made him very itchy and took a few days to clear.
