This paper details a shape memory polymer (SMP) synthesis and characterization process has been undertaken to develop a bio-medical material for fabricating non-invasive custom prosthetic components and orthosis devices. The glass transition temperature of a one-way SMP epoxy is tailored for external biomedical applications since human skin is sensitive to high temperature (> 45°C). The key shape memory properties of shape fixity ratio, shape recovery ratio and shape retention properties were comprehensively analyzed, and thermomechanical properties were verified. SMPs can be customized for the purpose; thus, SMP prosthetic and orthosis devices will be ideal for first aid and emergency treatments until proper medical attention is received. Finally, brief details of an SMP bone immobilization casting method are provided to explain the application further.