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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.
Additional markings are added to the positive model after the new plaster dries. This example shows markings for heel cup depth.
Additional markings added to the positive model. This example shows markings for metatarsal heads and appropriate distal frame length.
The positive models are ready for vacuum forming.
Frame material is cut into a general foot shape and added above the positive models. This example appears to be a carbon device.
Once the vacuum forming takes place, the frame material is pressed into the shape of the positive models.
After the vacuum forming process is finished, the frame has conformed to the congruency of the positive model.
Additional material used for an extrinsic rearfoot posting is cut and prepped.
This pressing machine is used to firmly adhere the additional material to the rearfoot.
The curvature of the heel cup area of the press.
The additional material is added to the inferior side of the frame’s heel cup, and pressure is applied.
A closer view of the process of pressing an extrinsic rearfoot posting.
Any extra material is cut and trimmed off the device’s frame.
Rearfoot posting angulation blocks.
These blocks come in varying degrees of angulation and are used while grinding the rearfoot to obtain a requested angulation in the rearfoot post.
Any rough surfaces of the frame and its posts and grinded down to create smooth and comfortable surfaces.
In this example, a heel cup is being ground into an ideal shape.
In this example, frame filler is being grinded down so the device will sit evenly and level on a flat surface.
In this example, the frame’s distal arch area is being grinded down.
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.
If a frame filler is requested, adhesive is added to the inferior side of the device and to frame filler.
In this example, adhesive is added to the dorsal side of these devices to prepare for applying a top cover.
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.
Devices and their top covers being prepped and organized.
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.