CUAFO - Defined CUSTOM URETHANE ANKLE FOOT ORTHOSES Custom Fabrication Procedures Techniques Advanced Materials

42 Year Old Male, reoccurring fracture at base of Fifth MH Record max circumference at instep & match or exceed in modification.

Measure Maximum Instep Circumference @ Full Dorsi – Flexion Match or slightly exceed in cast modification.

Cast maintaining desired alignment.

Understanding pathologies and management of the condition present are the primary responsibility of C.B.C.P.O Certified Orthotists, CO(c) & / or Prosthetists, CP(c) Recognized as members in good standing by The Canadian Board of Certified Orthotists & Prosthetists of the fabrication & materials applied are C.B.C.P.O. Registered Orthotic Technician, RTO(c) & / or Prosthetic Technician, RTP(c) .

A Mixture of Soap & Water is used as a release agent for the plaster negative. A mixture of 1 to 4 is sufficient using double application - Do not over apply soap!

Staple opening, seal, extend, Allow to set then flush with soap release mixture & drain excess. Allow soap release mixture to drain & dry for a minimum of 15 minutes. Repeat release application unless Using synthetic casting medium. Align your pipe mandrel and pour your negative cast in desired alignment. You should not allow cast to set for more than 24 hours before being stripped.

Carefully remove your plaster bandage negative & proceed to modification.

Relieve navicular & met. heads Build up maleoli Relieve navicular & met. heads Build up instep to max circumference & relieve achilles tendon Extend toes

A dry modified cast is required for processing using silicone or urethane Remember to form spacers prior to sealing the cast. Assuring your final modified cast is dry will greatly improve your results.

Apply 2 heavy cotton or casting socks as well as 1 nylon hose. This allows space for your inner lay-up prior to placing spacers & or structure. Holes should be placed in your LDPE spacers This allows saturation of the inner layers of the lamination.

LDPE strap pocket spacers add a nice touch to your finished product.

Dacron Felt can be used to provide extra rigidity where and when required!

Your next step is to seal your dried cast.

Apply 4 coats of sealer to your cast. Allow the 1st coat to dry for 10 minutes Allow the 2nd coat to dry for 10 minutes Allow the 3rd coat to dry for 10 minutes Apply the final coat & allow to dry a minimum of 30 minutes. Reduce cast sealer (2 Coats) Can be applied if using a release agent. Minimum release recommended. Do not over apply. Wipe the surface when dry! Or you will get the “Fish Eye”!

Insert structure if required Lay-up 10 nylon panty hose 2 nylgass LDPE Spacers Note holes in LDPE Insert structure if required 2 nyglass Adjust as necessary

Soak PVA Bag

make sure to invert and dry off using a paper towel or cloth. Before pulling PVA Bag make sure to invert and dry off using a paper towel or cloth. Return bag to original configuration and wipe dry using the same method. Allow your PVA to dry for a minimum of ½ hour before proceeding.

Choose the durometer best suited to your project Choose the durometer best suited to your project. Be sure to read & follow instructions.

Be certain to use pigment designed for the material you are using.

80 & 90 Durometer Urethane is a 2-1 (Part A – B) mix ratio.

Make sure you thoroughly mix your rubber.

While not necessary, we recommend de-gassing your rubber.

A minimum of 14 “ mercury of Vacuum is recommended.

Proceed with stringing out your rubber. Make sure you work the rubber into and under all spacers & or structure.

Avoid pooling unless required for extra localized rigidity. Aggressive stringing out of this higher viscosity material is required. Avoid pooling unless required for extra localized rigidity.

PVA should be removed after 4 hours or it may not be removable.

Offset your trim lines when removing Overlap Spacer. The “Nubs” can be trimmed, ground or left for traction. Edges should be finished with an 80 grit sanding cone. Non-Woven and Tycro Abrasives also give good results

Custom Dacron Billets / Hook & Loop Closure Straps. Strap Pockets, while not necessary provide a lower design profile.

Stitching can be done on a flat bed machine ~ A Long Arm Patcher is more practical.

Final fitting is performed by a qualified Orthotist. Minor trim lines can be adjusted easily.

Custom Fit = Custom Performance!

Improved Quality of Life!