Objective: The aim of this study was to examine the challenges and propose policy solutions to reduce complications arising from plaster casting in Iran. Methods: This study was conducted using two complementary approaches. Primary data were collected from patients with limb fractures who underwent casting. The information included demographic characteristics, type of fracture, method of casting, the person responsible for casting (physician or nurse), and complications observed after casting. The data collection instrument was a researcher‑designed checklist completed by the casting practitioner. National and international articles published within the past 10 years on casting complications and strategies for their reduction were reviewed, based on searches conducted in reputable databases such as PubMed, Scopus, and SID. Results: Findings showed that more than 82% of casts were applied by nurses, highlighting the necessity of specialized training for them. In addition, 85.5% of patients experienced at least one complication; the most common were pain, numbness, movement disorders, edema, and burning sensations under the cast. These results indicate an urgent need to develop standardized care protocols and to educate patients and their families to reduce complications. Conclusion: Adherence to standard casting principles and care education in Iran is insufficient, and policy reforms along with targeted interventions are essential to reduce complications and healthcare system costs. Conclusion: Adherence to standard casting principles and care education in Iran is insufficient, and policy reforms along with targeted interventions are essential to reduce complications and the associated costs to the health system.