The present invention is a device and method for manufacturing such a device which is a significant and non-obvious improvement over previous methods of removing plaster or fiberglass casts used for medical treatment. Current cast saw blades create enough heat through friction to burn patients upon the removal of a plaster of fiberglass cast. This device is an improved cast saw blade design which substantially reduces the risk of thermal burns to patients during the process of removing plaster or fiberglass medical casts. The present invention includes a saw blade design which inhibits a rise in the surface temperature of the cast saw blade during use by using a core material (i.e., Gallium) within the blade, the core material having a lower melting temperature than the blade material, as a heat sink.
