Exos Casting
Exos Casting at n1 physio
Modern casting without the plaster.
Traditional Alternative
Comfortable. Adjustable. Practical.
At n1 physio in Penrith, we offer the Exos bracing system from Enovis: a cutting-edge, thermoformable alternative to traditional plaster or fibreglass casts, built with Exos' advanced technology.
Exos braces are lightweight, waterproof, mouldable, and fully adjustable. Applied by our physiotherapists in under 20 minutes, they provide a comfortable custom fit and support for fractures and soft tissue injuries, all without the bulk, discomfort, or limitations of conventional casting. The low profile Exos material is easily concealed under clothing, allowing patients to go about their daily lives with confidence during recovery.
Why Choose Exos Casting in Penrith?
- Custom Fit: Exos braces are heat-moulded directly to your body for precise support and the best possible fit. The thermoformable material is gently moulded to the injured area, achieving a snug, cast-like consistency that supports proper healing.
- Adjustable: The Boa® dynamic closure system allows for easy tightening or loosening as swelling changes. Whether you are managing initial swelling or need tension modification during extended periods of wear, the adjustable Exos design adapts with you.
- Waterproof: Shower, swim, and stay active during your recovery. Unlike traditional plaster and fibreglass casts, waterproof Exos products won't deteriorate when exposed to water, thanks to the waterproof properties of the Exos bracing system.
- Lightweight & Low Profile: 25–50% lighter than plaster with a sleek, discreet design, with no bulky foam padding required. The light weight, low profile Exos material is easily concealed under clothing for everyday comfort.
- Easy to Remove: No cast saw required. The brace is easily removed for skin checks, physiotherapy, or brace hygiene, and reapplied in seconds.
- Hygienic: Antimicrobial and easily cleaned with soap and water. Easy skin inspection allows your physiotherapists to assess healing and monitor for complications like compartment syndrome without cutting away a cast.
We Support
A Better Alternative for Non-Displaced Fractures
Exos casting is ideal for injuries requiring stabilisation, including:
How It Works
1. Heating
The brace is gently heated using thermoformable technology until flexible.
2. Moulding
It is then gently moulded directly to the injured area for a snug, customised fit.
3. Hardening
The brace hardens within the next few minutes, providing full support with a secure and comfortable fit.
4. Adjustments
Adjustments can be made any time, without needing a new brace.
At n1 physio, we offer Exos casting as a superior, more comfortable option for fracture management. It’s quick, clean, breathable, and built for real life.
Want to know if Exos is right for you?
Call our clinic on (02) 4721 1976 or book online to speak with one of our physiotherapists.
Exos Casting
Key Features
- Custom fit via heat moulding using Exos’ advanced technology
- Boa® dynamic closure for easy adjustment
- Waterproof and easy to clean
- Lightweight, low profile, and hygienic
- No cast saw needed
- A much better alternative to traditional plaster and fibreglass casts
Why "n1"?
Why You Should
Choose n1 Physio
We believe that every person is unique.
Tailored Care From Day One
No generic plans, just treatment built around you.
Real Assessment Data
Objective testing and leading tools guide your rehab.
Experienced Therapists
Degree-qualified experts in general, sports, and performance care.
Strong Therapist-Patient Connection
We listen, explain clearly, and support you every step.
Ongoing Collaboration
Working with top specialists and surgeons to aid recovery.
Easy Rebates
Easy rebates – Claim via Medicare, WorkCover, and most private health funds.
Locations
Where to Find Us
We’re here for you at both our Penrith and South Penrith practices.
Penrith
105/64-68 Derby St, Kingswood NSW 2747
South Penrith
Southlands Shopping Centre
T11/2 Birmingham Rd, South Penrith NSW 2750
Traditional plaster and fiberglass casts are rigid, heavy, and cannot get wet, making daily activities like showering difficult. They also require a cast saw for removal. Exos braces, by contrast, use edge bracing technology and are made from thermoformable material that is lightweight, waterproof, adjustable, and easily removed without special tools. Scientific studies support the Exos system as a reformable solution and as a much better alternative to traditional casting, with the Exos advanced technology offering patients improved comfort and faster recovery outcomes.
Yes, Exos casting is suitable for both adults and children. Many parents prefer the revolutionary Exos bracing system for their children because it is waterproof, lightweight, and far more comfortable than traditional plaster or fiberglass alternatives. The adjustable Boa® closure system also makes it easy to manage fit at home, and the brace can be easily removed for bathing and skin checks. Our physiotherapists have experience fitting Exos braces for patients of all ages at our Penrith or South Penrith clinics.
Light activity and gentle movement are generally encouraged during recovery, and the waterproof, lightweight design of the Exos brace supports an active lifestyle. However, returning to sport or high-impact exercise will depend on the type of injury and your stage of healing. Your physiotherapist at n1 physio will guide you on safe activity levels and help plan a return to sport when the time is right.
The duration of wear depends on the nature and severity of your injury. Most fractures require immobilisation for 4 to 8 weeks, though your physiotherapist will provide a personalised timeline based on your healing progress. One of the key advantages of Exos braces is that they can be easily removed for scheduled physiotherapy sessions, allowing patients to begin guided movement and rehabilitation earlier than with traditional plaster casts.
While a doctor's referral is not always required, we recommend bringing any relevant imaging (such as X-rays) and medical reports to your appointment. Our sports physiotherapists will assess your fracture or injury to determine whether an Exos brace is the most appropriate option for your recovery. If further medical clearance is needed, our team can coordinate with your treating doctor.
Let's Talk
Move With Clarity
We believe better results come from treating the person, not just the injury. Whether you’re an athlete returning to performance, someone navigating chronic pain, or simply aiming to move better and live stronger, we’ll walk with you every step of the way.
