A quick Orficast tip for speedy orthotic fabrication

One of the most exciting features about Orficast is the ease and speed with which you can finish your orthosis. Directly applying hook and loop straps on wet Orficast with the help of some Orficast scrap material will considerably cut down the overall fabrication time of the orthosis.

Keep reading for all the details or go straight to the video.

What do you need?

  • An orthosis in Orficast or Orficast More (in this example we are using a thumb immobilisation orthosis)
  • A short piece of adhesive backed hook tape and a longer piece of loop tape
  • A heat gun
  • Pliers
  • Scissors
  • Two pieces of Orficast 3 cm (1.18″)


1. Prepare the base orthosis

  • Fabricate the orthosis, make sure it fits well and trim as needed.
  • Smooth or round the ends where you want to attach the straps.

2. Attach the adhesive backed hook tape to the base orthosis

  • Heat one piece of Orficast 3 cm (1.18″) with a heat gun, using the pliers.
  • Hold the adhesive backed hook tape with the pliers and briefly heat the sticky side with the heat gun.
  • Attach the hook tape to the heated piece of Orficast and cut neatly into the desired shape.
  • Use the heat gun to re-heat the hook tape on the Orficast side, place it on the orthosis and press together firmly. Be aware of the heat.

3. Attach the loop tape to the base orthosis

  • Heat the other side of the orthosis, where you will be attaching the loop tape.
  • Attach the piece of loop tape by pressing the underside into the heated Orficast orthosis.
  • Heat the other spare piece of Orficast with the heat gun and position it on the orthosis, completely covering the loop tape.
  • Firmly press together and make sure that all edges are secure.
  • Cut away the excess Orficast material for clean edges.
  • Alternatively, wrap the heated Orficast around one edge of the loop tape, completely covering it. Trim the edges and heat this up again with the heat gun before adhering to the orthosis.

4. Finish

  • Place the orthosis on the patient and fasten the strapping snugly.
  • Check the fit and trim the loop tape as needed.

Tips to keep in mind

  • Always apply firm and even pressure to the entire surface of the material when attaching the strapping. This will ensure a secure fit.
  • Avoid burning yourself by using the pliers to heat small pieces of material.
  • Make sure to not overheat the material with the heat gun.
  • Keep the edges of the orthosis and the hook and loop strapping clean and neat for optimal patient comfort.

Download this helpful guide with an overview of all steps:

(click to enlarge)

Leaflet showing how to attach hook and loop tape to an Orficast orthosis.

Watch the video:

Written by Marc Blij

Marc studied in Brussels and London and is a certified Orthotist and Prosthetist.

After working in an O&P lab at the Universities of Louvain and Brussels, he decided to set up his own O&P lab in Antwerp. For over 30 years, he ran his own practice, together with his wife.

Since 2006, Marc works at the Orfit Industries headquarters in Wijnegem (Belgium) as a Product and Educational Specialist in Orthotics & Prosthetics and Physical Rehabilitation.