The Process

The cast is filled with plaster

After the plaster sets up, the cast is removed

Sometimes we will measure and use a Cad Cam carving

Modifications are made to the mold to ensure the intended fit

A check socket will be pulled and trimmed to test the fit of the Prosthesis

After a good fit is obtained in the check socket, a carbon fiber / fiberglass laminated socket is fabricated

After the material is pulled over the mold, a PVA bag is pulled over

Acrylic resin and pigment are put under vacuum

The technician smooths the resin over the bag , ensuring even thickness of the resin

They will squeeze the bag above the mold, pushing more resin down

Continue to make sure to much resin doesn’t pool in areas

This socket had fabric pulled as the last layer and no pigment added to the resin

The socket is trimmed and smoothed to the desired trim lines

We have many different socket interfaces we can use

The is the process of making an AFO. A cast is taken and filled with plaster

After the plaster has hardened, the cast is removed and the mold is smoothed out.

The bottom of the foot is smoothed and evened

The toe plate is extended

Build-ups are added over bony prominences

Preparing for a flare at the top of the brace

build-ups are smoothed out

Copolymer plastic is heated in a special oven to make is plyable

It is carefully stretched over the mold to ensure even thickness

Vacuum is turned on

The plastic is sealed over the mold so that the vacuum can pull the plastic in tight to the mold

Excess plastic is trimmed

The AFO will stay under vacuum while it cools

AFO’s waiting to be trimmed off the molds