Patent ID: 8480604
Filing Date: 2013-07-09
Classification: A61F

Abstract:
1. A method of making an orthosis, comprising the steps of: preparing a plaster mold ( placing layers of material on the mold, then forming and removing the layers ( stapling and sealing the cast with plaster bandage ( setting the cast such that an angle between a foot portion and a leg portion is approximately 90 degrees ( sealing the cuts in the cast with the cast angled at about ( filling the cast with plaster, and then allowing the plaster mold to set ( stripping the cast away from a newly formed plaster mold ( smoothing the plaster mold with sheer forms and a sanding screen ( marking a finish height and heights for a back of the orthosis directly on the plaster mold ( drawing trim lines indicating dimensions of the orthosis directly on the plaster mold ( applying liquid plaster on a plaster bandage ( squaring off portions of the mold in an area of a footplate and building up portions of the mold in an area of a medial wall of the orthosis and a lateral wall of the orthosis ( sanding the entire mold ( recasting a modified leg mold ( heating and pulling a foam padding material over a calf portion of the leg mold and affixing the foam padding material to the mold ( cutting the foam padding material away from a strut ( skiving the foam padding material so that it tapers down to the plaster mold, and then skiving the foam padding material in the area of the footplate before pulling it on the plaster mold ( heating the foam padding material in the area of the footplate and pulling the heated foam padding material over the footplate, affixing or stapling the foam padding material to the footplate ( wrapping a clear plastic wrap over the orthosis, including over the foam padding material ( tracing trim lines drawn on the mold onto a material that is placed on the mold (