Before they travel to the desert Sam doesn't have a cast on his arm...as soon as they travel to the desert he has a cast on his arm. If you all remember when he was filming the movie he got into an accident in real life...so I'm assuming he broke his arm in real life and had to wear a cast...but they could of fixed it up a little better than making it so obvious.
If I remember right, Sam hurt his hand when Jetfire spacebridged them to Egypt, and Mikaela wrapped his hand right before Jetfire told them about the Tomb of the Primes. How she got the materials needed to wrap the hand, however, is never explained.
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