The Art of Moulding a Prosthetic Socket

21 Oct.,2024

 

The Art of Moulding a Prosthetic Socket

The process of moulding a socket is often seen as an art and requires great skill of a prosthetist. The socket needs to conform perfectly to the patient's stump so that it feels comfortable but still offers the necessary support.

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One way to create a prosthetic socket is by using the bubble-forming method: a thermoplastic socket material is heated in an infrared or convection oven until it starts to drop into a bubble-like shape. The bubble is then pulled over a positive mould of the patient's stump and is left to harden completely. This method results in a socket that neatly conforms to the patient's contours and gives the prosthesis a secure fit.

Follow along as we take you through all the steps of moulding a prosthetic socket using the bubble-forming method.

 

Step 1: Create a foam or plaster positive mould

Before you can start moulding any prosthetic socket, you need a good positive mould. Read our 5 tips on forming and positioning the perfect positive mould here.

 

Step 2: Prepare and heat the thermoplastic sheet

  1. Preheat your convection or infrared oven (for this article we are using an infrared oven) at the correct temperature. The diagram below gives an overview of all Orfit's socket materials and the corresponding heating temperatures. We also recommend reading our blog post about the ideal heating technique for Orfitrans Stiff.

(Click to enlarge)

 

 

  1. Remove the protective foil on both sides of the thermoplastic sheet, there is one on all Orfitrans products. This protective foil helps to prevent scratches on the material and protects against the absorption of moisture, but once you are ready to mould it is very important to remove it. Otherwise, the Orfitrans sheet will not drop in the oven.

 

  1. Wedge the thermoplastic sheet firmly into a supporting frame.

 

  1. Place the frame on a support rack and make sure that there is enough space for the bubble to form and drop in the oven.

 

  1. Place the sheet into the oven and allow the bubble to form. We usually recommend to let the bubble drop 2/3 the length of the socket.

 

  1. Take the sheet out of the oven with heat-resistant gloves.

 

 

Step 3: Pull the sheet over the positive mould

 

  1. Turn the bubbled sheet upside down with the convex side pointing upwards.

 

  1. Before you start moulding, take a look at the different sides of your positive mould. The socket shape usually has shorter and longer sides and you will need more thermoplastic material to cover the longer sides. You can position the bubble slightly off-centre over the top of the positive mould.

 

  1. Take account of the stiffness of your thermoplastic sheet:
    • Stiff materials: Use light pressure to pull the material down. Do this very slowly and make sure that you do not twist the material ' keep the sheet straight.
    • Soft materials: Support the material and make sure it does not drop too quickly.
      Give the thermoplastic the chance to conform to the mould in smooth and fluid movements in order to avoid bulging and unevenness.

 

  1. Let the sheet drop to the proximal sides of the mould.

  1. Activate the vacuum very slowly to reach a vacuum pressure of 0,2 bar.

 

  1. Then, let it drop further down to the edges of the vacuum baseplate.

 

  1. Optionally, you can lightly press the thermoplastic material against the positive mould, while wearing your gloves, to let the sheet conform even more.

 

  1. Let the thermoplastic sheet cool down entirely on the positive mould. The longer you can leave it to cool down the better, as this will guarantee that the socket keeps its shape. We usually recommend a cooling time of 24 hours.

 

Step 4: Remove the socket from the positive mould

When the socket has cooled down, saw off the material just above the proximal edge of the socket. Now you can slide the socket off or break out your positive mould.

 

Step 5: Finish the prosthetic socket

  1. Sand the edges of the socket with a router socket machine fitted with sanding rolls. Begin with a grit of 40 and then switch to a grit of 80.

 

  1. Use silicone polishing cones to give the edges a nice finish. Make sure to install your milling machine to a maximum of rpm. A higher amount of revs will generate too much heat and could potentially melt the material.

 

  1. Lightly reheat the edges with a heat gun to make them perfectly smooth.

 

Now your socket is completely finished and ready to be fitted to your patient.

We hope that this overview will help you to fabricate highly conforming prosthetic sockets that are as comfortable as they are supportive.

 

Written by Marc Blij

Marc studied in Brussels and London and is a certified Orthotist and Prosthetist.

After working in an O&P lab at the Universities of Louvain and Brussels, he decided to set up his own O&P lab in Antwerp. For over 30 years, he ran his own practice, together with his wife.

Since , Marc works at the Orfit Industries headquarters in Wijnegem (Belgium) as a Product and Educational Specialist in Orthotics & Prosthetics and Physical Rehabilitation.

 

Contact us for more product information or find your local distributor here.

 

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395mm 220V Socket Router Prosthetics Equipment

Prosthetics Equipment- Socket Router

This router motor has variable speed incl. motor brake For connection to a central dust suction unit with a minimum air flow of 20 m/s andan low pressure of 680 Pa Suction connection as per the machine requirement Router motor on a robust steel stand

Electronic Features Protective circuit according to German VDE Standard with low voltage release Emergency floor push stop On/Off router motor switch Main safety switch Appropriate cord length with safety plug

Basic Equipment Adjustable suction nozzle Shaft housing, long Spanner as per the machine requirements Threaded stud for router tools

Technical Data Space requirement (WXD) should not be more than 900 x mm Work height should not be less than mm Motor speed infinitely variable: 0- RPM or more Sound level should be less than 70 db Router shaft length should be equal or more than 430 mm Tapered spindle Router motor: 230 V / 50 Hz / minimum1KW

Attachment are available according to customer requirement

Note: Modification in size of Socket Router, Speed phase are available according to customer requirement.

 

For more Prosthetic equipment speed Socket Routerinformation, please contact us. We will provide professional answers.

  • Vibration-free thanks to their solid steel housing and solid construction

  • Durable motor which is designed for reliable performance, year after year

  • Electric height adjustment

  • Grinding and milling motor can be tilted 180° and rotated 165°

  • Integrated tool holder

  • Short and long milling shaft guards

  • Matching connector for 5/8" and M16 tools

  • Efficient dust protection thanks to built-in protective shaft guard with extra extension 'dust is extracted directly where it arises.

  • Suction hood with quick-change system

  • Your choice of accent colour (standard accent colour: anthracite grey)

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Q: Are you a manufacturer or a trading company?

A: We are the manufacturer, providing OEM & ODM service.

Q: How many years since your company start this business?

A: We began manufacturing prosthetics and orthotics parts since the year .

Q: Did your factory Register for export and import?

A: Yes. We applied full range of documents for exportation and importation.

Q: Did your factory and products approved by any testing or certification?

A: yes. We applied CE and ISO medical certification.

Q: May I apply to be one distributor or sole agent in our country to sell your products?

A: yes. This issue can be have a discussion.

Q: May I apply some free samples for testing before purchasing the full range of production?

A: Yes. sample order is acceptable. Also free sample order totally amount can't be over USD 50.

Q: How to deal for sample order and regular order?

A:Regaring the sample order only can be arranged by fast express, such as DHL UPS TNT and so on, the charges we can check for u! For the regular order, normally we choose BY AIR or BY SEA, EXW, FOB all are acceptable.

Q: How faster u can ship out the order?

A: For sample order normally within 3 days, regual order need to negotiate before every delivery issue settle down.

Q: Which way are acceptable for the payment?

A: TT/ Paypal / Western Union

Q: Can you provide us the best price?

A: Yes, each Item have differential pricing according to quantity.

Q:What's your Quality warranty?

A:Regarding the the metal parts all for 2 years, For silicone is 0.5-1 year.

Q: Can we visit your factory?

A: Yes, You are welcome to have a visit, u need to make an appointment with us before your coming.

 

 

If you are looking for more details, kindly visit Custom Prosthetic Solutions.