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Since earliest history, splintage materials have been used for immobilisation of injuries, especially fractures. The use of gypsum in this domain dates from the eleventh century and remains in common usage today. Lighter materials have been produced in an attempt to improve performance. The authors examined 180 patients comprising 90 upper limb and 90 lower limb with 30 in each of the three groups, traditional gypsum; fibreglass; and new polypropylene. The gypsum cast remains the cheapest at an average cost of £3.51 per patient compared to £7.18 for fibreglass and £7.45 for polypropylene (upper limb). However, the non‐cost advantages of the new product which were identified may make this extra expense worthwhile in selected cases.