Abstract: The present invention is an improved device to aid in the safe removal of casts from a patient. Even with the advent of safe cast removal tools, such as oscillating saws, there remains a distinct risk that a patient's skin will be cut or burned during cast removal. The present invention provides a protective shield that is mounted between the outer shell of a cast and a patient's skin to protect against cut-through and burning of the patient. The preferred protective shield comprises a woven expanded polytetrafluoroethylene fabric that has proven to be highly effective at avoiding cut-through by oscillating saws and the like.