Casting for DAFOs

We've created a guideline to help educate the importance of a good cast and how to obtain the perfect cast for the most intimate DAFO fit.

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Kate McCartney

Published 03 August 2026
Casting for DAFOs guide

What's unique about casting for DAFOs?

We believe the intimate contact of a thin, flexible, contoured brace, wrapping around the entire foot, provides more evenly distributed pressure for comfortable realignment than a typical rigid AFO. Creating a cast that accurately captures the desired alignment, shape, and volume of your patient's foot is the key to a well-fitting AFO. Here are a few useful tips to ensure a successful outcome for your patient.

Image of our DAFO 4 Softy brace with a posterior strap

 

Determining position

When capturing your patient's best position of function, the goal is to come as close to the ideal position as possible. If their range of motion or foot and ankle structure prevents them from reaching that goal, accommodations will need to be made. Always prioritize heel alignment. If the heel slips out of vertical when the forefoot is brought to level, use a shim to support the forefoot. After the best foot position has been established, capture the ankle angle for the finished brace in your cast. Ideal Position of Function shown as a vertical heel, level forefoot, and 3 degrees of dorsiflexion

 

Rehearsal

Before you get your casting tape, take a few minutes to rehearse with your patient. Practice correcting the foot and ankle to their best position of function. This rehearsal lets both you and your patient know what to expect during the actual casting process. Pictured a practitioner's hands on a patient's foot, manipulating it for rehearsal

 

Wrapping the cast

 

Tools needed:

  • Cotton stockinette
  • Fiberglass casting tape
  • Container of water
  • Hook-blade knife and extra blades

 

  • Channel buffer strip
  • Medical scissors
  • Electrical tape
  • Medical gloves
  • Casting pillow (optional)

Pictured the casting supplies listed arranged in a form that resembles a smiley face with its tongue out.

Note: When casting, we recommend using a channel buffer strip on the anterior of the leg and dorsum of the foot, extending it out past the toes and above the knee. This will give a safe channel to cut through when removing the cast from the patient.
 

 

When you begin casting, wrap the tape snugly around the midfoot, and ease the tension as you wrap toward the toes, being careful not to squeeze them together. Swoop the tape back to the midfoot and wrap snugly, high around the ankle and low around the heel, to avoid gaps. As you wrap up the leg, wrap a little looser to accurately capture the shape and volume. Pictured a foot wrapped in stockinette with a channel buffer strip seated on its anterior and dorsum. Fiberglass casting tape is being wrapped around the dorsum of the midfoot to start.

 

For videos on how to get a successful, even wrap, be sure to check out the Cascade Institution for Course 3: Casting & Scanning for DAFOs, or check out our YouTube for How-to videos on casting for DAFOs.

 

Defining the contours

As the tape begins to cure, use your fingers to push in and around all the key landmarks like the malleoli, met-heads, navicular, etc. To capture the plantar surface contours, consider using a casting pillow under your patient's foot. You can easily make your own with open-cell foam and cotton stockinette.

Pictured using a casting pillow
  Using the casting pillow

 

Finishing touches

Once you've removed the cast from the foot, tape it closed with the edges matched up. Place the cast in open air for another 2+ hours to allow it to fully cure.

Evaluate the cast

Check your cast carefully to esnure it meets the following criteria:

  • Smooth, even wrap with little distortion
  • Good definition of key landmarks and plantar surface contours
  • Ankle, hindfoot, and forefoot alignment at or close to the desired alignment of finished brace
  • Complete coverage from toest o above finished brace height
  • No distortion due to removing the cast before it has hardened

If your cast is not what you had planned, it's best to re-cast right away, while your patient is still in your office. It will only take a few minutes, and will ensure that the new cast captures the desired alignment, shape, and volume of your patient's foot, ankle, and lower leg.

Note: An accurate cast will best guarantee an intimate fit. Cast angles should be as close to the desired finished brace angles as possible.
If a cast is sent in that requests a correction of the ankle angle by 30° or more, Cascade Dafo will follow up with a call regarding brace fit.
Visuals that compare a cast with good alignment to a cast that should be recasted for better alignment

Take our course

For detailed casting techniques, take our free ABC-approved online course – Casting and Scanning for DAFOs – on the Cascade Institute and earn 1.5 CEUs. Through videos and interactive slides, you'll see:

  • Detailed videos of the casting process
  • Casting adult patients
  • Tips for working with and casting kids
  • Digital scanning techniques