Exos Cast Review | Cutting Edge Bracing Technology

Wednesday, June 19, 2019

Have you ever broken a bone and been stuck in a heavy, bulky fibreglass cast, or even worse, a plaster of paris cast? Thankfully, thanks to our EXOS casting technology, the days of fractures meaning you have to carry around a heavy cast all day are behind us. EXOS embraces the newest and most revolutionary casting, bracing and splinting technology.

Our clinics Physio Inq Penrith and Physio Inq South Penrith proudly offer the Exos casting and bracing system from DJO Global. The Exos bracing system is a revolutionary, thermoformable technology, offering an adjustable, waterproof and reformable solution for the treatment of fractures and other injuries requiring stabilisation. The Exos advanced technology allows our physiotherapists to mould the cast directly to you for the best possible fit, comfort and stabilization. The thermoformable material is light-weight, waterproof, can be easily cleaned, and is radiolucent (meaning you can have an Xray scan to check fracture healing without taking it off!). A much better alternative to a plaster cast or fibreglass cast for a non-displaced fracture. The Exos braces and casts are made from polymer and foam and take only 8 minutes to apply.

Our patients, especially the younger ones, benefit from the ‚"no cast saw required" removal and the waterproof properties of Exos braces allowing for easy skin and brace hygiene as well as involvement in water activities - yes you can shower, swim and surf in your cast! We proudly use and advocate Exos advanced technology as an alternative to traditional casting and splinting.

Watch here how easily and comfortable an EXOS cast is applied!

In the application stages, the brace can be warmed to the point of being almost rubbery in consistency. It is then gently moulded for a snug, comfortable custom fit. Over the next few minutes, the brace hardens to a firm, cast-like consistency, fully capable of supporting the injured part. Using the Boa® dynamic compression closure system, the brace can be tightened or loosened as required, maintaining a secure and comfortable fit.

The Exos brace can be easily removed without the use of a cast saw to examine the fracture/wound site.


Exos products can be fully immersed in water for prolonged periods, allowing patients to continue daily activities such as showering and swimming.

Lightweight and low profile

Exos material is 25% to 50% lighter than fiberglass or plaster.

The casts are easily concealed under clothes and are ideal for patients who have a hard time wearing traditional casts.


Exos uses the exclusive Boa® reel and lace dynamic closure system allowing for;

  • expansion for initial swelling and to reduce the risk of compartment syndrome.
  • tension modification for custom fit despite atrophy changes in soft tissue.
  • improved patient comfort and fit.

Antimicrobial and easily cleaned

The Exos can be washed with soap, so build up of bacteria and odour is greatly reduced.

EXOS casting has been vigorously tested in scientific studies to determine if efficacy. In a study, they used cadavers. They have the cadavers fractures and then placed half of them in traditional fibreglass casting and the other half in EXOS casting. They then put forces on them and performed Xray scans to determine the displacement (movement) of the fractures and it was identical between the traditional casting and the EXOS casting.

It is also a great alternative to traditional thermoplastic splinting giving a much neater look and a more comfortable fit. This can be useful for sprains and strains as well as other tendon injuries.

To make an appointment with one of our physiotherapists please visit and enquire at our clinics in Penrith & South Penrith

visit DJO Global who are the biggest and most trusted suppliers for EXOS Casting

This article was originally written by Chris Slaviero From Physio Inq Penrith & Physio Inq South Penrith

Share the article