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The technician smooths the new additional plaster by hand. It is done by hand because the technician can intimately feel the contours of the patient’s positive model.
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Additional markings are added to the positive model after the new plaster dries. This example shows markings for heel cup depth.
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Additional markings added to the positive model. This example shows markings for metatarsal heads and appropriate distal frame length.
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The positive models are ready for vacuum forming.
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Frame material is cut into a general foot shape and added above the positive models. This example appears to be a carbon device.
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Once the vacuum forming takes place, the frame material is pressed into the shape of the positive models.
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After the vacuum forming process is finished, the frame has conformed to the congruency of the positive model.
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Additional material used for an extrinsic rearfoot posting is cut and prepped.
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This pressing machine is used to firmly adhere the additional material to the rearfoot.
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The curvature of the heel cup area of the press.
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The additional material is added to the inferior side of the frame’s heel cup, and pressure is applied.
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A closer view of the process of pressing an extrinsic rearfoot posting.
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Any extra material is cut and trimmed off the device’s frame.
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Rearfoot posting angulation blocks.
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These blocks come in varying degrees of angulation and are used while grinding the rearfoot to obtain a requested angulation in the rearfoot post.
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Any rough surfaces of the frame and its posts and grinded down to create smooth and comfortable surfaces.
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In this example, a heel cup is being ground into an ideal shape.
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In this example, frame filler is being grinded down so the device will sit evenly and level on a flat surface.
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In this example, the frame’s distal arch area is being grinded down.
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Comparisons between the device and positive model are made to ensure the highest levels of congruency. This example demonstrates a comparison of heel cup and lateral flange of a UCBL device.
Another lateral view of the accurate congruency of this UCBL device.
A posterior-medial view of the congruence of arch area of the device to the positive model.
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If a frame filler is requested, adhesive is added to the inferior side of the device and to frame filler.
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In this example, adhesive is added to the dorsal side of these devices to prepare for applying a top cover.
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Modifications being applied and customized to devices. These examples show the grinding/buffing of a forefoot extension (left) and of a heel spur pad (right) for smooth transition.
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Devices and their top covers being prepped and organized.
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This example demonstrates a wide variety of devices with varying requested congruence (patient to patient) and modifications, for example: heel spur pads, forefoot extensions, heel to toe padding, varying densities of frame filler and extrinsic rearfoot posting.