Overview of Orthopedic External Fixation Materials: From Traditional Plaster to Smart Polymers, Clinical Choices Grow More Diverse

With the ongoing advancement of trauma orthopedics and reconstructive surgery, external fixation materials—key adjuncts in fracture reduction, dislocation management, and skeletal deformity correction—have seen continuous evolution in both composition and performance.

Plaster Bandages: Classic, Durable, and Economical, Yet with Obvious Limitations

Made from calcined gypsum powder coated onto gauze bandages, plaster‑of‑Paris bandages are the oldest and most widely recognized external fixation material. They are softened by immersion in water, wrapped around the limb, and harden upon cooling to form a rigid shell. Their main advantages are low cost and high conformability, allowing close adaptation to body contours. However, inherent drawbacks—poor breathability, relatively low rigidity, bulky weight, and susceptibility to moisture—have gradually limited their use in long‑term immobilization or early functional rehabilitation. Today, they are mostly reserved for short‑term stabilization or initial post‑operative protection.

Polymer Composite Materials: Lightweight, High‑Strength, and Radiolucent

In recent years, polymer splints and bandages made from high‑elasticity fiberglass fabric impregnated with polyurethane resin have become a mainstream upgrade in external fixation. These materials cure rapidly upon exposure to water or ambient moisture, achieving a final hardness significantly greater than that of plaster while weighing much less. Their open‑mesh structure provides excellent breathability, greatly improving patient comfort. More importantly, they are radiolucent, allowing clear X‑ray or CT imaging without removal of the fixation, so that callus formation and alignment can be monitored throughout treatment. In addition, their washable surface and neat appearance better meet modern patients’ expectations for quality of life.