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

2. 42 Year Old Male, reoccurring fracture at base of Fifth MH
Record max circumference at instep & match or exceed in modification.

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

4. Cast maintaining desired alignment.

5. 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) .

6. 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!

7. 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.

8. Carefully remove your plaster bandage negative & proceed to modification.

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

10. 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.

11. 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.

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

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

14. Your next step is to seal your dried cast.

15. 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”!

16. 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

18. Soak PVA Bag

19. 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.

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

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

22. 80 & 90 Durometer Urethane is a 2-1 (Part A – B) mix ratio.

23. Make sure you thoroughly mix your rubber.

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

25. A minimum of 14 “ mercury of
Vacuum is recommended.

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

27. 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.

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

29. 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

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

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

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

33. Custom Fit = Custom Performance!

34. Improved Quality of Life!