Cast saw injuries

Traditional cast removals can be nerve-racking for the person having to wear a cast and the person removing the cast. It can be stressful to have a cast placed on and taken off, hoping the person knows what they are doing. Sometimes patients have to get cast multiple times since some casts must be cut off for exams, sometimes multiple times through the healing process. And it’s not reassuring to know that a cast saw can cut skin and cause other injuries.

Causes Of Cast Injuries

Cast saw burn on toddler

Studies have shown that resident physicians have less than 1 hour of training when it comes to cast application and removal. Consequently, improper cast removal techniques can cause injuries to the patient. Cast removal injuries depend on the casting material, the thickness of the cast, the thickness of the padding underneath and the experience of the person removing the cast. Any inconsistencies in any of those factors could lead to the overheating of the saw blade, skin lacerations or improper cutting techniques which can cause the injuries.

Most patients don’t realize that when the cast is removed, the saw blade can reach temperatures of up to 150 degrees Fahrenheit and sometimes higher. The thicker the layers of cast material that are applied make it more difficult to remove, causing the blade to become incredibly hot, potentially leading to 1st, 2nd or even 3rd degree burns on the skin.

The thickness of the cast padding underneath can also cause removal injuries. For example, if the physician doesn’t place the padding thick enough, the patient could feel the heat from the blade and even possibly get burned.

Not only can the cast saw blade cause thermal burns, they can also cause nicks to the skin or even lacerations. If the physician using the cast saw isn’t familiar with the proper cast removal techniques and cutting depth, they can cause injuries to the patient’s skin. This is especially true with those patients who have thin skin, like the elderly.

Avoiding Cast Injuries

There are techniques for safe cast removal. However, not every physician knows them. Fortunately, there is one way to get around all of these issues: ask your provider for an ActivArmor 3D printed cast. With ActivArmor, you don’t have to worry about cast saws at all. ActivArmor devices come in 2 pieces and are placed on by simply placing the 2 pieces together and securing them in place. No cast padding, messy plaster or rough fiberglass.

ActivArmor casts are simple to order, scan and apply. Additionally, they are reusable, biocompatible, and adjustable for changes in swelling. Learn more about ActivArmor casts and where you can get one by clicking the button below.