The system invention describes a support and improved method of application and removal. The support, comprised of a network of flexible, non-porous, multi-lumen tubing interlaces at a plurality of junctions to form a lattice structure. Apertures designed to accommodate boney prominences also permit air or water to reach the skin underneath and encourage rapid fluid flow internally through the lattice. A hydrophobic, thermal-resistant, flowable padding layer is injected within a secondary lumen to the lattice structure, spanning its complete surface area. As a result, the breathability of the support is not affected by this padding layer because it mirrors the apertures of the lattice. At least one liquid is injected into the structure and configured to transform into a solid when acted on by an external mechanical stimulus.

The system invention describes a support and improved method of application and removal. The support, comprised of a network of flexible, non-porous, multi-lumen tubing interlaces at a plurality of junctions to form a lattice structure. Apertures designed to accommodate boney prominences also permit air or water to reach the skin underneath and encourage rapid fluid flow internally through the lattice. A hydrophobic, thermal-resistant, flowable padding layer is injected within a secondary lumen to the lattice structure, spanning its complete surface area. As a result, the breathability of the support is not affected by this padding layer because it mirrors the apertures of the lattice. At least one liquid is injected into the structure and configured to transform into a solid when acted on by an external mechanical stimulus.

An improved thermoformable orthosis apparatus for being selectively formed and applied and removed having offset zipper closures on two shell members for improved hinging and opening and access for initial application and forming when malleable and for removing and reinstalling when hardened.

To provide a surgical fixing material which has excellent breathability and ease of application, and which is not susceptible to causing rigid wrinkles when fixing bent sites. A surgical fixing material having a hardened layer 5 which comprises a plurality of holes 3 having a surface area of 5 mm.sup.2 or more.

To provide a surgical fixing material which has excellent breathability and ease of application, and which is not susceptible to causing rigid wrinkles when fixing bent sites. A surgical fixing material having a hardened layer 5 which comprises a plurality of holes 3 having a surface area of 5 mm.sup.2 or more.

A reusable thermoplastic cast may include: a core material (10) having a net shape as a result of molding a synthetic resin elastomer into a net shape by of injection molding or press-working; and a structure (20), which consists of a polycaprolactone composite material and is molded to surround the outer circumferential surface of the core material (10) by insert injection. Example embodiments improve breathability by forming a cast in a net shape and provide a cast which is structurally sturdy and appropriate for mass production by molding the cast by, e.g., insert injection.

A reusable thermoplastic cast may include: a core material (10) having a net shape as a result of molding a synthetic resin elastomer into a net shape by of injection molding or press-working; and a structure (20), which consists of a polycaprolactone composite material and is molded to surround the outer circumferential surface of the core material (10) by insert injection. Example embodiments improve breathability by forming a cast in a net shape and provide a cast which is structurally sturdy and appropriate for mass production by molding the cast by, e.g., insert injection.

A formable cast (100), brace (180) or splint is provided herein which comprises a padding (101), an outer shell (103) spaced apart from the padding, and a ridge (109) disposed along the perimeter of the shell. The ridge, shell and padding define an interior space (115), with a curable polymeric material disposed in the interior space. The curable polymeric material undergoes a phase transition, upon curing, from a liquid or gel phase to a substantially rigid solid phase. The cast (100), brace (180) or splint may be readily customized to the patient by fitting the cast to the patient's body, positioning the cast in the desired orientation, and curing the curable polymeric material through exposure to actinic radiation or by other suitable means.

A cast system, which includes: a padding layer configured to be disposed within a cast and support a portion of a patient's limb; a casting material which hardens around the padding layer and form an outer shell of the cast surrounding the patient's limb; and a wire saw configured to be disposed within the cast and extend along a longitudinal axis of the cast. The wire saw has a cutting surface which is at least partly enclosed by a plastic sheath. By enclosing the wire saw cutting surface in a plastic sheath, the saw does not lock up during the cutting operation, cutting is facilitated, allowing for easy and safe removal of the cast by pulling at least one end of the wire saw so as to cut through the outer shell of the cast.

A cast system, which includes: a padding layer configured to be disposed within a cast and support a portion of a patient's limb; a casting material which hardens around the padding layer and form an outer shell of the cast surrounding the patient's limb; and a wire saw configured to be disposed within the cast and extend along a longitudinal axis of the cast. The wire saw has a cutting surface which is at least partly enclosed by a plastic sheath. By enclosing the wire saw cutting surface in a plastic sheath, the saw does not lock up during the cutting operation, cutting is facilitated, allowing for easy and safe removal of the cast by pulling at least one end of the wire saw so as to cut through the outer shell of the cast.