Exos Brace

Exos Thermoformable Braces - Modern New Cast Alternative for Wrist, Hand & Thumb Fractures

Exos braces by DJO Global represent the future of fracture immobilization—a revolutionary thermoformable technology that combines the superior support of traditional casting with the convenience, comfort, and adjustability of modern orthotic design. Often called an Exos removable cast, the Exos brace can be custom-molded directly to your body using heat, creating a perfect fit that's waterproof, lightweight, radiolucent (X-ray friendly), and fully adjustable throughout treatment. OrthoTape.com offers the complete line of Exos braces including wrist fracture braces, short arm braces, thumb spica braces, and boxer's fracture braces—all featuring the innovative Boa Fit System for micro-adjustable precision support.

Understanding Exos Thermoformable Technology

What Makes Exos Braces Different?

Exos braces utilize advanced thermoformable plastic that becomes pliable when heated to 200°F (93°C), allowing healthcare providers to mold the brace directly to the patient's anatomy for a custom fit. Once cooled to room temperature, the material hardens into a rigid, supportive structure that immobilizes the injury while remaining lightweight and comfortable. This is why many clinicians and patients 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: Unlike plaster or fiberglass casts that must be completely replaced if fit changes, Exos braces can be reheated and remolded as swelling decreases or increases. This eliminates the need for multiple cast changes, reducing material waste and healthcare costs while ensuring optimal fit throughout the entire healing process.

Waterproof & Hygienic: Exos braces are fully waterproof, allowing patients to shower, bathe, and even swim without covering or protecting the brace. The antimicrobial-treated material reduces odors and can be easily hand-washed and dried with a hairdryer. Traditional casts become ruined if wet and develop odor from trapped moisture and bacteria.

Radiolucent (X-Ray Friendly): Exos braces do not need to be removed for X-ray imaging. The thermoformable material is radiolucent, allowing clear visualization of bones during follow-up appointments without the hassle of cast removal and reapplication. This saves time and ensures continuous immobilization.

Lightweight & Low-Profile: Exos braces weigh significantly less than plaster casts and are more streamlined than fiberglass, making them more comfortable for extended wear and easier to fit under clothing and sleeves.

Micro-Adjustable Boa Fit System: The integrated Boa dial system allows for precise, incremental adjustments to accommodate swelling fluctuations throughout the day. Simply turn the dial to tighten or press to release—no tools required. This ensures consistent compression and support without pressure points.

Lockable for Compliance: Optional Boa Locking Ring Kit snaps over the Boa dial to prevent unauthorized removal, ideal for pediatric patients and less compliant individuals who might be tempted to remove the brace prematurely.

Exos Brace Product Line - Complete Guide

Exos Wrist Fracture Brace with Boa

Comprehensive wrist immobilization brace designed for stable wrist fractures and injuries requiring controlled wrist motion. Provides support for the radiocarpal and radioulnar wrist joints while allowing functional hand use.

Indications: Minimally displaced or stable distal radius fractures, distal ulna styloid fractures, carpal bone injuries (lunate, pisiform, triquetral fractures), scapholunate dislocations, triangular fibrocartilage complex (TFCC) tears, radiocarpal ligament injuries, wrist sprains requiring immobilization

Features: Thermoformable for custom fit, Boa Fit System for micro-adjustability, openings at thenar eminence (base of thumb) and palmar crease for range of motion and comfort, waterproof and antimicrobial-treated, radiolucent for X-rays, available in sizes XXS through XL (black only)

When to Use: Stable wrist fractures not requiring surgery, post-operative wrist immobilization, wrist ligament injuries, alternative to traditional casting

Exos Short Arm Fracture Brace with Open Thumb

Classic short arm brace providing wrist and forearm immobilization while leaving the thumb free for functional use. Ideal for fractures to the distal radius or distal ulna that don't involve the thumb.

Indications: Distal radius fractures (Colles' fracture, Smith's fracture), distal ulna fractures, wrist fractures, acute wrist injuries, post-operative wrist stabilization

Features: Thermoformable custom molding, Boa Fit System, open thumb design for functional grip, thenar eminence and palmar crease openings, waterproof and easy to clean, lockable with optional Boa Locking Ring Kit, available in adult and pediatric sizes

Pediatric Version: Specifically sized for children with smaller hand and wrist dimensions. Available in multiple colors to make wearing a brace more appealing for young patients. Same advanced features as adult version.

When to Use: Wrist and forearm fractures, post-cast transition, injuries not involving thumb, pediatric fractures

Exos Thumb Spica Fracture Brace

Specialized brace that immobilizes the thumb in adduction along with the first metacarpophalangeal (MCP) joint and first carpometacarpal (CMC) joint, while providing secondary support for wrist joints.

Indications: Scaphoid (navicular) fractures (confirmed or suspected), thumb fractures, first metacarpal fractures, CMC joint arthritis (basal joint arthritis), gamekeeper's thumb (UCL injury), DeQuervain's tenosynovitis, carpal tunnel syndrome (CTS), post-operative thumb immobilization

Features: Thermoformable for anatomical fit, adjustable thumb strap for precise immobilization, increased forearm length for better stabilization, Boa Fit System, waterproof and antimicrobial, radiolucent, lockable for compliance

Short vs. Long Thumb Spica: Short version provides wrist and thumb support. Long Thumb Spica II extends further up the forearm for enhanced immobilization of more severe injuries or post-surgical cases requiring maximum stability.

When to Use: Scaphoid fractures, thumb injuries, CMC arthritis, post-thumb surgery, carpal tunnel syndrome requiring wrist and thumb rest

Exos Boxer's Fracture Brace

Ulnar gutter brace specifically designed to stabilize fractures of the 4th and/or 5th metacarpal bones and their respective MCP joints. The unique design allows caregivers to achieve greater than 70 degrees of flexion at the MCP joints for optimal healing position.

Indications: Boxer's fracture (5th metacarpal neck fracture), 4th metacarpal fractures, 5th metacarpal fractures, phalangeal fractures of ring and pinky fingers

Features: Thermoformable ulnar gutter design, dorsal hook-and-loop secure tab for brace stability, adjustable straps across web space and around 4th/5th digits, trimmable finger section for desired range of motion, Boa Fit System, waterproof and antimicrobial

When to Use: Boxer's fractures from punching injuries, 4th/5th metacarpal fractures, ulnar-sided hand fractures, alternative to ulnar gutter splinting

Exos Brace vs. Cast - Full Comparison

How Exos Braces Are Applied - Thermoforming Process

Step 1 - Heating: Open and unfold the Exos brace. Heat in Exos oven at 200°F (93°C) for approximately 3-4 minutes until pliable. Brace should be warm but not too hot to handle comfortably.

Step 2 - Application: Ensure skin is completely dry. Fit brace on patient's extremity in the desired position. Remove slack in Boa lace by turning the Boa knob. Do NOT fully tighten until brace has cooled to room temperature to avoid indentations.

Step 3 - Molding: While brace is still warm and pliable, mold it to the exact contours of the patient's anatomy. Apply gentle pressure to create custom fit around bony prominences and soft tissue. Secure hook-and-loop straps in desired positions.

Step 4 - Cooling & Final Adjustment: Allow brace to cool and harden to room temperature (approximately 5-10 minutes). Once fully hardened, tighten Boa knob to desired tension for optimal support. Attach optional Boa Locking Ring if needed for compliance.

Important: Exos braces should be applied by qualified orthopedic technicians, physicians, or under direct medical supervision. Improper application can result in inadequate immobilization or skin complications.

Who Should Use Exos Braces?

Orthopedic Patients: Individuals with stable fractures, post-operative immobilization needs, or injuries requiring custom-molded support who want the convenience of a waterproof, adjustable alternative to traditional casting.

Active Individuals & Athletes: People who need to maintain hygiene through showering/swimming, want lightweight support that doesn't interfere with daily activities, or require the ability to adjust compression throughout the day.

Pediatric Patients: Children who benefit from colorful, less intimidating braces, need waterproof options for bathing, or require lockable systems to prevent premature removal.

Post-Surgical Patients: Those transitioning from rigid casting to adjustable support, needing frequent X-ray monitoring without brace removal, or requiring reformable braces as swelling changes.

Patients with Compliance Concerns: Individuals who struggled with traditional cast restrictions, developed skin issues or odor problems with previous casts, or need the psychological benefit of a removable (but lockable) Exos cast alternative.

Important Considerations & Contraindications

Professional Application Required: Exos braces must be applied by qualified healthcare providers with proper training in thermoforming techniques. Improper heating, molding, or fitting can result in inadequate immobilization or skin injury.

Not for All Fractures: Exos braces are designed for stable fractures and injuries. Unstable fractures, severely displaced fractures, or injuries requiring surgical intervention may need traditional rigid casting or surgical fixation.

Skin Precautions: Ensure skin is completely dry before application. Do not over-tighten Boa system as excessive pressure can cause skin breakdown. Monitor for signs of pressure sores, numbness, or circulation problems.

Heat Sensitivity: Patients with reduced sensation, diabetes, or peripheral neuropathy require extra caution during thermoforming to prevent burns from hot material.

Why Buy Exos Braces from OrthoTape?

Authorized DJO Global Dealer

We're an authorized dealer for DJO Global Exos products, guaranteeing 100% authentic braces with full 8-week manufacturer warranty covering defects in workmanship and materials. Unlike unauthorized sellers, we source directly from DJO Global.

Professional-Grade Products

Our Exos braces are the same professional-grade products used by orthopedic surgeons, emergency departments, urgent care facilities, and certified orthotic technicians nationwide.

Expert Support & Guidance

Our team can help you select the appropriate Exos brace for your specific injury and provide guidance on sizing. Call 800-580-9887 (M-F 9:30 AM – 5 PM EST) for assistance.

Fast, Urgent Shipping

We understand fracture patients need braces urgently. Most orders ship within 1-2 business days. Upgrade shipping options available at checkout for faster delivery when needed.

Complete Product Line

We stock the full range of Exos braces including wrist, short arm, thumb spica, and boxer's fracture models in all available sizes (XXS through XL, adult and pediatric).

Frequently Asked Questions

Do I need a prescription for an Exos brace? While Exos braces are medical devices typically prescribed by physicians, you can purchase them for use under medical supervision. A prescription may be required for insurance reimbursement.

Can I apply an Exos brace myself? No. Exos braces require professional application by qualified orthopedic technicians or physicians trained in thermoforming techniques. Improper application can result in inadequate immobilization or injury.

How long does an Exos brace last? With proper care, Exos braces last throughout the entire treatment period (typically 4-8 weeks for fractures). The 8-week warranty covers defects in workmanship and materials, not damage from normal wear, abuse, or alterations.

Can I shower and swim with an Exos brace? Yes! Exos braces are fully waterproof. You can shower, bathe, and swim without covering or removing the brace. Hand-wash and air-dry (or use hairdryer) to maintain hygiene.

What if the brace becomes too loose as swelling decreases? Simply tighten the Boa dial for a snugger fit. If significant looseness persists, the brace can be reheated and remolded by your healthcare provider for a better fit without needing a completely new brace.

Is the Exos brace as strong as a traditional cast? Yes. When properly molded, Exos braces provide equivalent immobilization to traditional fiberglass casts while offering superior adjustability, comfort, and convenience.

Can I get X-rays with the Exos brace on? Yes. Exos braces are radiolucent, meaning X-rays can pass through the material for clear bone visualization without removing the brace. This saves time and maintains continuous immobilization.

What sizes are available? Exos braces are available in sizes XXS through XL for adults, with separate pediatric sizing for children. Measure hand circumference and refer to sizing charts. When between sizes, size up as the brace can be molded for a custom fit.

Is the Exos brace considered a removable cast? Yes — many clinicians and patients refer to the Exos as a removable cast or Exos 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.

Browse our complete selection of Exos thermoformable braces above. Whether you need a wrist fracture brace, short arm brace, thumb spica, or boxer's fracture brace, OrthoTape.com has the professional-grade Exos products you need for modern, convenient fracture immobilization with the comfort and adjustability traditional casts can't provide.