Product Overview
• Product : Orthoses are devices that address muscle or joint problems. It provides an additional support to prevent or correct a
deformity. These devices can either be custom made according to the specifications of the customer or bought off the shelf.
Foot Orthoses
Step 1 : Orthotist analyses the feet to understand the range of motions
and pin point weakness or pain points. 3D impression in foam and
Technical details are staged before step 2 and step 3 respectively
Step 2 : The production department fills the foam impression from step 1
with plaster and creates an exact model of the feet staged before step 5
Step 3 : Different types of polyurethane (a light weight thermoplastic) are
used to form the shape as per the technical details from step 1. The
assembled design is then staged before step 4
Step 4 : The assembled design is then covered with a sheet of glue and
placed in a vacuum press to activate the adhesive and remove the excess
air to compress it tightly. The assembled design is staged before step 5
Step 5 : The assembled orthosis from step 4 is then placed over the
mould from step 2 and placed in the vacuum press. Made to measure
orthosis is then staged before step 6
Step 6 : The made to measure orthosis is lined with Latex foam and staged
before step 7
Step 7 : Soft polyurethane layer is attached to the orthoses using
hypoallergenic glue and staged before step 8
Step 8 : The orthoses from step 7 is buffed along all sides and staged
before step 9
Step 9 : The orthoses are packaged and shipped to the customer
Knee Orthoses
Step 1 : Orthotist examines the leg of the patient and measurements are
taken.
Step 2 : Technician uses plaster bandages to create a mould in the shape
of the patient’s leg. The plaster bandages are quick dry and once dried,
the mould is filled with plaster to create a model of the leg as per the
measurements taken in step 1. The model is staged before step 3 and 4.
Step 3 : Technical markings are made on the model and lightweight
aluminum joints are placed for the mobility of orthosis. The assembled
orthosis is staged before step 5.
Step 4 : A sheet of high memory plastic is run through the oven and
decorative pattern chosen by the patient is transferred on to the heated
plastic sheet. The plastic sheet is staged before step 5.
Step 5 : The orthosis from step 3 and plastic sheet from step 4 are
assembled in step 5 by using a vacuum press that joins the two. The
orthosis is now ready for the next production step and is staged before
step 6.
Step 6 : Finishing touches are given to the orthosis by cutting, binding and
buffing out the rough edges. The orthosis is then staged for step 7.
Step 7 : Straps are attached to the orthosis and the product is ready for
final step in production.
Step 8 : The orthoses are packaged and shipped to the customer
Process Flow Diagrams