Why cast and crutches for 6 weeks after big toe fusion surgery ? definitely not what was discussed in advance ....

Stable fusion: Bones need to be held together and stabilized in order to fuse together as a single bone. Moving bones don't fuse. Depending on the method that was used to stabilize your big toe joint fusion site, it is not unusual for crutches - and perhaps a cast - to be used for some period of time during your postoperative healing course.

This could be needed: Depending on the fixation used, your age, general health and the quality of your bone, you my require 6 weeks or longer with cast/boot and crutches to heal. The 2 bones must be kept in close proximity and still relative to each other in order for the fusion site to heal. Sometimes a bone stimulator is required but this is not expected. Smoking can delay healing of the fusion site as well.