Flexara Labs engineers precision custom splints, waterproof casts, and therapy aids — manufactured locally in Worcester and delivered within 24 hours. For clinics that cannot wait. For patients who deserve better.
Your team spends 40 minutes fabricating every thermoplastic splint by hand. National suppliers take 5–14 days. Small clinics cannot afford bulk minimums. We eliminate all three problems with one local supplier who delivers the next morning.
Generic casts and splints are made for an average body that does not exist. Your recovery deserves better. We manufacture devices to your exact measurements — lighter, more comfortable, and fully waterproof — delivered directly to your home within 24 hours.
Every day a patient waits for a splint is a day of lost recovery. Every hour a therapist spends fabricating thermoplastic is an hour not spent treating patients. The system is failing clinics — and no one has fixed it locally. Until now.
Thermoplastic fabrication was the best available technology in 1985. Today's patients deserve better. Today's therapists deserve better. The tools exist to make that happen — Flexara Labs is the bridge.
The therapist heats a sheet of thermoplastic in hot water, cuts it to rough size with scissors, molds it directly on the patient's limb for 10–15 minutes while it cools, trims the edges with a heat gun, adds velcro straps, adjusts for fit. Total time: 35–45 minutes of unbillable clinical labor per device. Every single time.
For clinics that order prefabricated splints from national distributors — the process is: submit a purchase order, wait 5–14 business days, receive a box of Small/Medium/Large sizes, discover the patient's wrist does not match any of them, call to return the wrong sizes. Meanwhile the patient has been waiting two weeks without a device.
Traditional plaster and fiberglass casts are heavy, itchy, non-breathable, and completely destroy on contact with water. Patients shower in plastic bags. They skip showers entirely. They develop skin infections under the cast. They cut the cast off early because the discomfort is intolerable. None of this is necessary anymore.
You give us the patient's measurements. We engineer a precision-fit orthosis from medical-grade polymer, packaged and labeled for clinical use, at your clinic door within 24 hours. No fabrication. No waiting. No wrong sizes. The therapist spends 10 minutes fitting instead of 40 minutes fabricating — and the patient leaves with a device that was built for their exact anatomy.
20 products across 5 categories — all manufactured locally in Worcester from medical-grade polymer. Photos of each device will appear here as production begins. Every item is available now for trial orders.
Holds the entire hand in the intrinsic-plus position — wrist extended, MCPs flexed, IPs straight, thumb abducted. Prevents contracture in stroke, TBI, and burn patients. Custom-fit to exact hand measurements. Worn during rest and sleep.
Palm-side wrist support holding the joint in prescribed extension — fingers completely free. Used for wrist fractures post-cast, carpal tunnel night splinting, de Quervain's tenosynovitis, and post-surgical protection. 3 standard sizes plus custom.
Immobilizes thumb CMC and MCP joints, all four fingers free. Used for de Quervain's tenosynovitis, first metacarpal fractures, gamekeeper's thumb, and CMC arthritis. 3 standard sizes plus patient-specific custom option.
Channel-shaped splints immobilizing the ring/pinky (ulnar) or index/middle (radial) fingers and corresponding wrist. Used for boxer's fractures and metacarpal injuries — one of the most common ER-referred splints. 3 sizes, left and right.
Small tubular sleeve holding the DIP joint in full extension for 6–8 weeks to heal a ruptured extensor tendon (mallet finger). Worn continuously — removing it even once resets the healing clock. 10 sizes from pinky to index finger.
Ring-style splint worn like jewelry, physically limiting PIP hyperextension in swan neck or boutonniere deformities. Designed for rheumatoid arthritis and hypermobility patients — allows full daily function while protecting unstable joints. Sizes 4–11.
Two TPU loops strapping an injured finger to the adjacent healthy finger. The healthy finger acts as a dynamic splint — protecting from sideways deviation while allowing normal flexion/extension. Used for finger fractures, PIP sprains, and post-surgical finger protection.
Lightweight adjustable wrist cuff for prescribed strengthening exercises — flexion, extension, radial and ulnar deviation. Padded inner layer, hook-and-loop closure. Labeled as a wellness and exercise aid. Two sizes. Supports post-cast removal and repetitive strain recovery protocols.
Fully circumferential ABS polymer cast custom-fit to the patient's exact wrist and forearm geometry. Completely waterproof — shower, swim, live normally. Lighter than plaster, breathable, removable for wound care. Manufactured from ISO 10993-1 certified medical-grade ABS — the same biocompatibility standard as FDA-listed devices.
Custom-fit full forearm cast from wrist to elbow in ISO 10993-1 certified medical-grade ABS. Designed from patient limb scan or measurements. Lighter than plaster, fully breathable through lattice pattern, completely waterproof. Custom ventilation cutouts for wound access and bone stimulator compatibility.
Six-piece wide-grip handles (32mm and 38mm) restoring eating independence for stroke, Parkinson's, MS, and arthritis patients. Top-five OT-prescribed ADL item nationally. Fork, knife, spoon, teaspoon, ladle, spatula — all daily meals covered.
Two-piece ADL set providing 3× mechanical torque for patients with reduced grip. The key turner converts any standard key from pinch grip to gross grip operation. The jar opener provides 95mm high-friction surface for kitchen independence. Top-five OT ADL prescription.
72mm high-grip disc providing 4× mechanical advantage over direct cap contact. Six raised radial ribs grip standard and large prescription bottle caps. Essential for geriatric independence and Parkinson's patients — medication adherence is directly linked to the ability to open the bottle independently.
Universal wide-diameter grip aids sliding over any pen, pencil, paintbrush, or household tool. Three inner diameters: 8mm, 10mm, 12mm — covers virtually all common instruments. Prescribed for writing retraining post-stroke, art therapy, vocational rehabilitation, and tremor management.
Three-piece dressing independence set: button hook, zipper pull extension, and dressing stick. Button hook converts a pinch-grip task into a gross-grasp motion. Zipper pull extends small tabs into large loops. Dressing stick assists with pants, socks, and shoes without bending. Essential for hip and back surgery patients.
Three-level progressive resistance rings targeting individual finger joints. Light, Medium, and Firm resistance from the same design at different wall thicknesses. Most prescribed hand therapy home program tool for post-surgical, post-stroke, and arthritic hand protocols. Adult and pediatric sizing.
Ergonomic cylindrical handle with horizontal grip ridges for progressive full-hand strengthening. Anti-slip ribbed surface prevents compensatory finger repositioning. Standard and compact sizes. Used for post-fracture, post-cast removal, stroke recovery, sports injury, and geriatric deconditioning protocols.
Four graduated resistance rings (Extra-Light through Firm) for full-hand palm strengthening. Compact 60mm form factor sits on a patient's nightstand and gets used multiple times daily — the single best tool for improving home exercise compliance. 60mm adult and 48mm pediatric.
15° rocker arc foot trainer for proprioceptive training, ankle rehabilitation, and fall prevention. Load-tested to 120kg. Anti-slip textured top surface. Used for ankle sprain, ACL post-surgical rehab, post-stroke balance retraining, and fall prevention programming for adults 65+.
Lumbar roll maintains spinal lordosis during prolonged sitting — prescribed for chronic low back pain and post-discectomy posture retraining. Knee positioning wedge prevents full extension contracture post-TKR and ACL surgery. Both use honeycomb infill for correct compression feel.
Six 60mm panels with calibrated textures: smooth, raised dots, parallel ridges, wave pattern, mesh grid, and deep grid — each targeting a specific sensory input level. Used for pediatric sensory integration therapy, autism spectrum OT, tactile defensiveness, and developmental coordination disorder programs.
4×4 precision pegboard with 16 round pegs in two diameters — 6mm fine and 9mm standard. Used for fine motor coordination assessment, pinch and lateral grip training, bilateral hand coordination, in-hand manipulation, and pre-vocational hand skills. One board, two difficulty levels, from pediatric to geriatric rehab.
All 20 products available now for trial orders · Product photos will be added as production begins · Custom sizing available on all splints and orthoses
Bundled care packages save you ordering time, reduce delivery trips, and give your patients a complete recovery toolkit in a single box — delivered to the clinic or directly to their home within 24 hours.
All bundles delivered in one box within 24 hours · Custom bundles available on request · Clinic accounts qualify for volume pricing on repeat orders
Bundled kits reduce your ordering time, our production time, and shipping cost — while giving patients a complete home program from day one. Each kit ships in a single labeled box with instructions included.
Clinic bulk ordering: Order any kit in multiples of 5 for an additional 10% volume discount. One delivery, one invoice, one contact. We deliver the full order within 24 hours.
No purchase orders. No account setup. No minimum quantities. No 14-day approval windows. Getting Flexara products into your clinic is designed to be as fast as your patients need their recovery to be.
Call, text, or fill out our contact form. Tell us the diagnosis, the device type, and the patient measurements. We confirm within 2 hours during business hours — often within minutes.
Every product is manufactured to your specifications in Worcester using precision-calibrated medical-grade polymer. No warehouse inventory — made fresh for this patient, this prescription, this measurement.
We deliver personally across Central MA and Greater Boston within 24 hours. First-time orders — you inspect the device on delivery. Pay only if you are satisfied with the quality and fit. Zero financial risk.
The therapist fits the device in 10 minutes instead of 40. The patient leaves with a custom-fit orthosis built for their anatomy. Recovery starts today. Running low? Text us by 6pm — restocked next morning.
Whether you run a clinic, treat patients daily, or are recovering yourself — Flexara Labs has devices and tools built for your exact situation.
Stock your clinic on demand with no minimum orders and no upfront payment on trial orders. 24-hour restock when supplies run low. One local contact who answers their phone — not a national call center. Your supply chain problem is solved.
Your patients leave with a home program that actually has the right devices. Custom-fit splints sized to your exact prescription, delivered before their next session. You spend 10 minutes fitting instead of 40 minutes fabricating. That is 30 minutes of clinical time back per patient — every single time.
Recovery does not stop when you leave the clinic. Get the same clinic-quality devices delivered directly to your home — for grip strength, balance training, daily independence, or custom splinting. No prescription required to order directly. Your recovery, on your timeline.
Children's hands grow rapidly. National suppliers stock 2–3 pediatric sizes. We print the exact size your patient needs — this week, not next month. Sensory boards, fine motor pegboards, pediatric splints, and grip tools sized for small hands and growing children.
Parkinson's, post-stroke, MS, and TBI patients need ADL tools that restore independence. Medication openers, adaptive utensils, key turners, and custom resting hand splints — delivered before your patient's next session. The device that gives a Parkinson's patient back their morning independence is the most important tool in your clinic.
Post-surgical hand rehab, ankle rehab, ACL return-to-sport — we carry the custom splints, balance boards, and resistance tools your athletes and post-surgical patients need for home programs. Delivered the day after surgery if needed. No stock delay between prescription and healing.
We combine advanced polymer manufacturing with a local delivery model that national suppliers structurally cannot replicate. Every device is made to order, not pulled from a warehouse.
Every device is manufactured to order locally in Worcester. No warehouse stockouts, no national shipping windows, no backorder delays. Order by 6pm — delivered next morning.
We manufacture to exact measurements — not to Small, Medium, or Large. A splint built for your patient's exact wrist circumference and prescribed angle fits correctly the first time. Better fit means better compliance. Better compliance means better outcomes.
All skin-contact products use ISO 10993-1 certified biocompatible polymers. Our waterproof casts use the same ABS specification as FDA-listed devices. Your patients are protected. Your clinic is protected.
Every first order to a new clinic is a trial order. We deliver personally. You inspect the device. You pay only if you are fully satisfied with the quality. That is the standard we hold ourselves to — because we are certain we will meet it.
I discharged a post-TFCC repair patient on a Friday and had the full resistance ring progression on my desk Monday morning. That kind of turnaround changes how I write home programs — I can prescribe the exact tools I want knowing they will be there before the patient's next session. In 11 years of hand therapy practice this has never happened with any other supplier.
We expanded our OT program and needed ADL tools immediately. Flexara delivered a complete trial set in 24 hours with zero upfront cost, and the quality was exactly what our patients needed — durable, comfortable, the right sizes. We have been restocking weekly ever since. The response time alone is worth switching from our national supplier.
My husband has Parkinson's and was waking up every morning unable to open his medication bottles. I called Flexara on a Wednesday and had the bottle opener Thursday afternoon. He opens them himself now. Something that small makes an enormous difference in how a person feels about their own independence. That is what this company actually delivers.
Our sports medicine caseload runs heavy on post-surgical hand and ankle cases. I started stocking the balance boards and finger trainers two months ago. Patients are completing their home programs at a measurably higher rate — the tools actually arrive before the patient loses motivation. That is a clinical outcome difference, not a supply preference.
I run a pediatric OT practice and sensory tools are always either backordered or overpriced from national suppliers. The Flexara sensory board set has the right texture calibration for my integration protocol, the quality held up after six weeks of daily clinic use, and when one panel cracked they had a replacement at my door within 24 hours. That kind of support simply does not exist with anyone else I order from.
I had rotator cuff surgery in March and my PT prescribed a grip strengthener and wrist exercise aid for home. My wife called Flexara directly and had both tools at the house before my first post-op appointment. I was able to start the home program immediately instead of waiting two weeks for a medical supply delivery. Recovery felt like it was on my timeline, not a shipping carrier's.
First-time clinic orders are always trial orders. We deliver personally. You inspect on delivery and pay only if you are satisfied. That is how confident we are in what we build — because your patients deserve devices that actually fit, arrive on time, and support the outcomes you are working toward.
Tell us what you need — a specific device, a product category, or just a question about whether we can help. We respond within 2 business hours. Every first clinic order ships as a trial — you pay on delivery, only if satisfied.