10 Inventive Ways of Using Orficast Thermoplastic Roll

It is well-known that Orficast and Orficast More are great for making all types of orthoses for fingers, thumbs, and hands. But did you know that you can also use Orficast for non-orthotic use in many creative ways? Here are just a few ideas to get you started . . .

Orficast is a unique thermoformable thermoplastic material on a roll. It offers extreme comfort for your patients and is very easy to use. This thermoplastic material is ideal for all applications of finger and/or thumb orthoses and supportive bandage wraps.

 Orficast Characteristics

  • Thermoplastic material on a 3-meter roll.
  • Excellent elasticity in two directions.
  • Adaptable when needed.
  • Thin and breathable fabric-like material
  • Easy to cut.
  • Self-adhesive capacity, especially when dry heated.
  1. Help Strapping Materials Stick

Orficast is a very sticky material when heated directly with the heat gun. It is an excellent interface between the completed orthosis and hook-and-loop strapping materials. To firmly attach loop straps, place heated Orficast around the loop strap and adhere it directly to the orthosis. Heat Orficast and also the adhesive-backed hook tape to bond together more securely.

Orficast forms an excellent interface between strapping materials and the finished orthosis.

  1. Make Straps Easier to Grip

You can use Orficast to increase the size of the loop strapping to make it easier for someone with limited pinch to grasp, like in a patient with arthritis or weakness of the thumb muscles. Cut a narrow piece of Orficast and apply it over the sides of the loop strap.

Use Orficast to make loop straps bigger and easier to grasp.

How Orficast Works and Looks

  • Material on a roll allows to use circumferential wrapping and molding technique. Time saving. No need to make a pattern.
  • Perfect size (width) for small and larger orthoses. Can accommodate different sized fingers and different orthotic designs.
  • Allows precise modeling conform the patient anatomy, for example in the web space.
  • Orthoses can be adapted when corrections are needed. Avoids waste of material.
  • Soft touch feeling and smooth edges. Lightweight. Allows ventilation. Prevents maceration of the skin. Excellent patient comfort and compliance.
  • Allows to easily cut small pieces to use as reinforcement of the orthoses when desired.
  • Overlapping seams are not perceptible on the inside. Application of multiple layers raises rigidity and stability of the orthoses.
  1. As a Hinge

Roll Orficast into hinges and use them to link two parts of an orthosis together at the joint axis level. Flatten the edges of the rolled Orficast to make it easier to adhere to the orthosis. Use pliers to create the bending spot if necessary. Heat both the ends of the Orficast tube and the orthosis with the heat gun and secure the hinge into place.

The orthosis will allow motion at the joint, and you can easily add components for dynamic and/or static progressive orthoses to increase passive range. The Orficast hinge protects the joint from compression and distraction forces.

Roll Orficast into a narrow tube and use it as a hinge.

  1. To Block Undesired Motion

Rolled Orficast can also be placed to block undesired motion as in a Dart Thrower’s Motion Orthosis.

When placed correctly, it blocks pure wrist flexion and extension but allows movement in the Dart Thrower’s place of radial deviation and extension towards ulnar deviation and flexion. In this way, it allows the scapho-lunate ligament to heal without excessive strain.

In a Dart Thrower’s Motion Orthosis, a rolled piece of Orficast can be placed to block undesired motion.

  1. Finger Caps

Orficast can be made into finger caps for protection, over sensitive fingertips, or over amputated fingertips. Make the dorsal or volar side slightly longer to help with strapping or use Coban wrap tape to keep the cap in place.

  1. Finger Cuffs for Mobilization Orthoses

When fabricating a mobilization orthosis, use Orficast to create comfortable finger cuffs for each individual finger.

Cut narrow strips of Orficast, heat them in the water bath, and fit them around the patient’s finger. When hardened, place the elastic around the cuff and cover with another piece of heated Orficast to ensure it stays in place. Or simply fold the Orficast around the elastic and then mold around the finger with the string already in place.

Orficast as finger cuffs for mobilization orthoses.

Orficast Recommended Applications

  • Perfect to use in case of traumatic and orthopaedic conditions that require quick and easy orthoses.
  • Recommended as first aid product for quick immobilization and stabilization after injury.
  • All types of immobilization finger orthoses and hand-based wrist and thumb orthoses.
  • Precise modeling and snug fit prevent pressure points.
  • Allows to fabricate static progressive orthoses to regain range of motion.
  • Also recommended to use in case of fragile skin, for example, for patients suffering a poly-arthritic condition.
  • Fabrication of larger orthoses will require dry heat for bonding.
  1. Finger Separators

Create finger separators in a resting orthosis with rolled pieces of Orficast.

Add the Orficast to the orthosis, and position the patient’s hand while the material is still soft. This way, the patient can find the most comfortable finger positioning. When hardened, the Orficast tubes will help to maintain this positioning.

A resting orthosis with Orficast separators.

  1. Easy-To-Grip Handles

Wrap Orficast around pens and markers to make them easier to grab and hold on to.

A custom Orficast handle for a pen.

  1. On Zippers

Zipper tabs can be hard to grab for patients with a weakened grip. Using Orficast to increase the size of a zipper tab on a backpack or suitcase can make an enormous difference. You can make it as large as needed; simply heat a piece of Orficast, wrap it around the zip tab, and let it harden.

  1. Enforce Knots

When using elastic thread for a mobilization orthosis, it is very important that the knots do not loosen as this could affect the traction. Enforce the tied knots with a piece of Orficast so they do not come apart.


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