By L.W. Barnes
Orthotic materials are constantly evolving and so are the techniques required to fabricate devices.
When a new material comes on the scene, industry experts say that training and common-sense techniques go a long way toward understanding how best to handle it—whether the issue is safety or the durability of the finished device.
Steve Hill, CO, an orthotist based in Asheville, NC, is a consultant who instructs students nationwide in the technical aspects of fabrication.
“When it comes to the introduction of new materials to the industry, education is absolutely critical,” Hill said.
He and other insiders point to the recent introduction of prepreg carbon fiber material (carbon fiber that is first impregnated with resin) as an example. Prepreg requires more know-how than the previous materials manufacturers relied on for wet laminations: fiber, carbon and polyester, or acrylic resins. Depending on the application and the skill of its handler, prepreg is at turns easier or harder to work with, and more accurate or less trustworthy.
“It’s a challenging material to work with but the results can be great,” said Greg Mattson, CEO and managing partner of Fabtech Systems, a central fabrication manufacturer of custom orthoses and prostheses located north of Seattle, WA.
Mattson, who also works as an industry educator, says that having standards and consistency in the use of new, cutting-edge materials is key. “Because it’s a challenging [new material], if you don’t implement it systematically, you have a high probability it will fail,” he said. “I’ve seen many companies that jump on the bandwagon with something new and it flops. The product was good, but they didn’t implement it into their current process in a managed manner.”
Frank Friddle, Jr., CO, is the owner of Friddle’s Orthopedic Appliances, an O&P manufacturer based in Honea Path, SC. His grandfather, W.D. Friddle, Sr., started in the profession in the 1930s, when fabrication materials consisted largely of leather and steel. Since that time, Friddle, his father, and now his daughters have witnessed the evolution of materials and have learned to experiment and adapt. Today, like most in the field, they work with thermoplastics.
Just the way a fighter pilot prepares before taking a multimillion dollar aircraft off the ground, technicians should review a mental checklist every time they work with a new material, experts like Friddle say.
The first priority is safety. Are hazardous materials involved? Resin dust, for example, is toxic if inhaled. Acetone is also dangerous to the skin and eyes.
Fabtech recently released a nontoxic solvent wipe to replace an acetone product. Although the product is simple to use, Mattson said they’ve had to educate their customers about safety in handling toxic chemicals.
A material’s physical properties also should be considered. Is it soft and flexible, or rigid? Will it fracture under a heavy load? Or will it break if you trim a sharp radius? Is it easily adjustable if heated?
“You have to know the modifications that can be made,” Friddle said.
And what kind of equipment will be used to heat the material? Infrared, convection, or an industrial baking oven?
Each, Friddle says, offers advantages based on the particular material used.
“For a thicker gauge, I prefer convection,” he said.
Because new materials can be costly, measuring is particularly important. This can prevent overbuying as well as ensuring that, when working with a hazardous material, there is less to handle and dispose of.
“Most manufacturers offer detailed instruction sheets,” Friddle said. “But there are so many variables in every facility—from ambient temperature to storage conditions—[that can affect the outcome]. You will probably have to make some tweaks to get the optimum use in your own situation.”
Sponsored by an educational grant from JMS Plastics Supply
