Decision-

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Introduction Index Making Textiles Metals Chemicals Review
Materials Materials
Tools

Materials
for Orthotic
and
Prosthetic
Application
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INTRODUCTION: HOPE Careers Consortium
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Materials Materials
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HOPE Careers Consortium is a partnership of five institutions of higher education that is building
exciting new programs that will provide valuable career education and training in the Orthotics,
Prosthetics, and Pedorthics (O&P) sector. The five institutions are:

Baker College – Flint, Michigan

Century College – White Bear Lake, Minnesota
Oklahoma State University Institute of Technology – Okmulgee, Oklahoma
Spokane Falls Community College – Spokane, Washington
St. Petersburg College – St. Petersburg, Florida

This Open Educational Resource (OER) is provided with the goal of helping learners more fully understand the many
types of materials that can be used when selecting, designing, adjusting, and fabricating orthotic and prosthetic devices.

This workforce product was funded by a grant awarded by the U.S. Department of Labor’s Employment and Training
Administration. The product was created by the grantee and does not necessarily reflect the official position of the U.S.
Department of Labor. The U.S. Department of Labor makes no guarantees, warranties, or assurances of any kind, express
or implied, with respect to such information, including any information on linked sites and including, but not limited to,
accuracy of the information or its completeness, timeliness, usefulness, adequacy, continued availability, or ownership.
Produced 2016.
INTRODUCTION: Objectives
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OBJECTIVES
Upon successful completion of this Open Educational Resource
presentation, you will be able to:
 Evaluate material variables to determine how best to meet a
patient’s need.
 Compare and contrast open-cell and closed-cell foam structures.
 Describe the purpose of a durometer scale.
 Describe the purpose of a Mohs scale.
 Describe the properties and uses of leather in O&P devices.
 Explain how leather is measured.
 Describe the properties and uses of cork in O&P devices.
 Describe the properties and uses of carbon composites.
 Contrast and compare the key properties and uses of common
thermoplastics in the O&P field.
 Compare and contrast the differences between thermoplastic and
thermoset.
 Describe the properties and uses of foams and gels.
 Describe the properties and uses of textiles.
 Compare and contrast the differences between metals that are
malleable and metals that are ductile.
 Compare and contrast the attributes of polyester, vinyl ester, and
epoxy resins.
 List protective measures to take when working with chemicals and
dust.

NOTE: The length of time it will take a learner to complete this self-study resource depends greatly on the learner’s style and pace of learning
as well as his / her current understanding of the subject matter. However, an estimate has been made that a learner could thoroughly read and
review this material, as well as participate in all self-assessment opportunities, in approximately six hours.
INTRODUCTION: Course Management
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MATERIALS for ORTHOTIC and
PROSTHETIC APPLICATIONS
There was a time when leather, wood, and steel were the primary
materials used when designing and fabricating orthotic and prosthetic
devices. Not anymore. In the O&P field, thermoplastics and other synthetic
materials provide varying combinations of strength, weight, flexibility, and
energy return, while composites and metal alloys facilitate lighter, stronger
artificial limbs.
So, what materials should be selected for any given patient? Factors to
consider include the patient’s age, weight, general health, occupation,
hobbies and aspirations, where they live (cold or warm climate), and
insurance coverage.
And because there are so many material choices available and each has its
own advantages and disadvantages, decisions must be made to balance
material qualities, such as firmness, flexibility, rigidity, adjustability, strength
… and so on.
This presentation helps to address some of these issues by providing:
(a) information about the considerations to make when working with
orthotic and prosthetic materials,
(b) categories and descriptions of materials used in the O&P industry:
natural, synthetic, textiles, and metals,
(c) information about the chemicals used in O&P devices, and
(d) Helpful, self-assessment sections.
For ease in navigation, each tab above is a link to its respective section.
Although you can review the material in any order you prefer, we
recommend you review the “Decision-Making Tools” section prior to
accessing the materials sections.
Note: In addition to the review section at the end of the entire presentation,
each materials section and the chemicals section includes a link to Quizlet,
which enables further self-assessment. Quizlet is a fun and easy online
learning resource featuring “STUDY” tools and “PLAY” tools. Visit the site to
further your understanding of the information presented here.
INTRODUCTION: Orthotic and Prosthetic Terms
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ORTHOTIC DEVICES PROSTHESIS TYPES

Orthotic devices include: Types of prostheses include:

• FO—Foot Orthosis • TM—Transmetatarsal Amputation

• AFO—Ankle Foot Orthosis • AD—Ankle Disarticulation
• KAFO—Knee Ankle Foot Orthosis • TT—Transtibial
• HKAFO—Hip Knee Ankle Foot Orthosis • TF—Transfemoral
• KO—Knee Orthosis • HD—Hip Disarticulation
• HO—Hip Orthosis • HP—Hemipelvectomy
• WHO—Wrist Hand Orthosis • WD—Wrist Disarticulation
• EWHO—Elbow Wrist hand Orthosis • TR—Transradial
• SEWHO—Shoulder Elbow Wrist Hand Orthosis • ED—Elbow Disarticulation
• SO—Sacral Orthosis • TH—Transhumeral
• LSO—Lumbar Sacral Orthosis • SD—Shoulder Disarticulation
• TLSO—Thoracolumbosacral Orthosis • IT—Interscapulo Thoracic
• CTLSO—Cervical Thoraco Lumbar Sacral Orthosis
INDEX
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Below is a list of terms/product names used in the O&P field as they relate to materials. Each word links to a section within this document where
the word is referenced or defined. Terms/product names mentioned multiple times will link to the section where they have the most application.

Acetal Compressive Strength Iron P-CellTM Resins

Kevlar® PPT® Rubber Note: Registered
Acrylic Co-Polymer trademark information
Acrylic Resin Copper KorexTM Pe-Lite® Silicone can be found at the
Acrylonitrile Butadiene Corium Kydex® Perlon Stockinette Spenco® conclusion of this
Styrene (ABS) Cork Lamination Plastazote® Stainless Steel presentation.
Aliplast® Cork Compounds Lay-Up Polycarbonate Styrene
Aluminum Cushion Cork Leather Polyethylene Terephthalate SubOrtholen®
Aramid Dacron Felt Malleability Glycol (PETG) Surlyn®
Basalt Braid Dacron Strap Microcel Puff® Polyester Resin TL-2100
Bidirectional Carbon Fiber Ductility Mohs Scale of Hardness Polyethylene Tensile Strength
Birko Cork Durometer Molding Temperature Polyethylene Foam Thermo CorkTM
Carbon Elasti-CorkTM MulticorkTM Polymer Thermoplastic Elastomers
Carbon Composites Epoxy Resin Neoprene Polypropylene (TPE)
Carbon Fiber Ethyl Vinyl Acetate (EVA) Nickelplast-S Polyurethane Thermoplastics
Carbon Fiber Braid Evazote® Nyglass Stockinette Polyurethane Foam Thermoset
Carbon Fiber Reinforced Fiberglass Nylon Polyvinyl Chloride (PVC) ThermoSKY®
Plastic/Polymer (CFRP) Fiberglass Tapes and Sleeves Nylon Stockinette Poron® Titanium
Carboplast® Foams Open-Cell Foam Pre-Preg Unidirectional Carbon Fiber
Closed-Cell Foam Gels OrtholenTM Proflex Velcro®
Collagen Impact Strength Orthoplast® Proflex with Silicone Vivak®
Yield Strength
DECISION-MAKING TOOLS
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DECISION-MAKING TOOLS
DECISION-MAKING TOOLS: Overview
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Here you will find links to information O&P professionals utilize when considering their material options.
For ease in navigation, each area noted below links to its respective section.
Review the sections in any order you prefer.

MATERIAL DUROMETER SCALE

VARIABLES

Materials:
Design and
OPEN- vs. CLOSED- TEMPERATURE
CELL FOAMS Structure (Conversion)
Considerations

MEASUREMENT
MOHS SCALE (Conversion)

THERMOSET
vs.
THERMOPLASTIC
DECISION-MAKING TOOLS: Material Variables
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MATERIAL
VARIABLES: Here are variables O&P professionals consider when determining their selection of materials.
Strength Note: Additional variables continue on the following slides.
Density
Durability
Hardness
STRENGTH DENSITY
Stiffness Types of strengths measured in the O&P field: A consideration when determining how to make
Thickness
(1) Tensile strength: the resistance of a material to the O&P device as light as possible without
Molding Temperature
break under tension, (2) Compressive strength: the sacrificing strength, stiffness, and durability.
Corrosion Resistance
resistance of a material under compression, Calculation: The material’s weight per unit
(3) Yield strength: the lowest stress that produces of volume. Related to density is specific
Grindability
a permanent deformation in a material, and (or relative) gravity, which is the ratio of the density
Sheet Size
(4) Impact strength: the ability of the material to of a substance to the density of a given reference
Malleability
support or sustain an applied load. material (usually water.)
Ductility
Lamination
OPEN- vs. CLOSED-
CELL FOAMS

DUROMETER SCALE DURABILITY HARDNESS

The ability to withstand wear, pressure, or damage. With rubbers, polyurethane, and plastics, hardness
MOHS SCALE More specifically, it refers to resistance-to-fatigue is described as the material’s resistance to
failure and repeated ability to withstand loading permanent indentation and is determined through
THERMOSET VS. and unloading cycles. the use of a durometer (measurement and
THERMOPLASTIC instrument). With metals, hardness can be
determined through the use of a Mohs scale.
CONVERSION
CHARTS:
Temperature
Measurement
DECISION-MAKING TOOLS: Material Variables
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MATERIAL
VARIABLES: Note: Additional variables continue on the following slide.
Strength
Density
Durability
Hardness STIFFNESS THICKNESS
Stiffness The rigidity of a structure; the extent to which “Iron” is a thickness-measurement tool used in
Thickness it resists deformation, bending, or compression the shoe industry and when dealing with leather.
Molding Temperature when a material is loaded. The stiffer a structure, Calculation: One iron is equal to 1/48 inch.
Corrosion Resistance the less flexible it is and the less likely Synthetic O&P materials, such as thermoplastics
Grindability that deformation will occur. and foams, are sold in sheets of varying
Sheet Size Calculation: Load divided by deformation. thicknesses.
Malleability
Ductility
Lamination MOLDING TEMPERATURE CORROSION RESISTANCE
OPEN- vs. CLOSED- The recommended temperature at which The degree to which the material is susceptible
CELL FOAMS materials should be heated for optimal molding. to chemical degradation. Contact with body
Note: This is typically different from the melting fluids is an important consideration.
DUROMETER SCALE temperature.
MOHS SCALE

THERMOSET VS.
THERMOPLASTIC

CONVERSION
CHARTS:
Temperature
Measurement
DECISION-MAKING TOOLS: Material Variables
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MATERIAL
VARIABLES:
Strength
Density
Durability
Hardness
GRINDABILITY MALLEABILITY
Stiffness Defines whether or not the material can be used The property of a metal that enables it to be
Thickness on a grinder. hammered, bent, pressed, or rolled into sheets
Molding Temperature without breaking.
Corrosion Resistance
Grindability
Sheet Size SHEET SIZE DUCTILITY
Malleability The size and depth to which a given sheet of The property of a metal that enables it to stretch
Ductility material is cut –typically available in a full or half without damage.
Lamination sheet, roll or wheel.
OPEN- vs. CLOSED-
CELL FOAMS

DUROMETER SCALE
LAMINATION
The number of layers or materials glued together to form a single sheet. Laminating materials with
MOHS SCALE different characteristics together can often produce better functioning materials.

THERMOSET VS.
THERMOPLASTIC

CONVERSION
CHARTS:
Temperature
Measurement
DECISION-MAKING TOOLS: Open- vs. Closed-Cell Foams
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MATERIAL
VARIABLES:
Foamed thermoplastics are formed by forcing nitrogen or some other gas into the plastic during heating. They can be open-cell
Strength or closed-cell structures. Below is a chart that provides an overview of the key differences in the two types of cell foams.
Density
Durability OPEN-CELL FOAM CLOSED-CELL FOAM
Hardness Pores are connected to form an interconnected Pores are not interconnected, but instead “piled”
Stiffness network, which allows air to flow between the cells. together.
Thickness
Molding Temperature When air fills the space, the foam becomes soft. Bubbles of trapped air are surrounded by cell walls,
Corrosion Resistance making the foam more rigid.
Grindability Breathable, soft, spongy. Lightweight and washable.
Sheet Size
Malleability Low Density: ½ to ¾ of a pound per cubic foot. Medium Density: 2 - 3 pounds per cubic foot.
Ductility Absorbs moisture. Does not absorb fluids/ moisture.
Lamination
OPEN- vs. CLOSED- Resistant to compression deformation. Susceptible to compression.
CELL FOAMS One of the most common open-cell foams used in O&P One of the most common closed-cell foams used in
is Poron®. It is a polyurethane foam that is O&P is Plastazote®. It is a polyethylene foam and is
DUROMETER SCALE compression-set resistant, fungal resistant, and lightweight, non-toxic, odorless, and will not absorb
breathable. Typical applications for Poron in the O&P water. Typical applications for Plastazote in the O&P
MOHS SCALE field include custom and prefabricated orthoses, field include custom and prefabricated foot orthoses,
prosthetic padding, and biomechanical supports. soft-touch skin contact material (used in braces, splints,
THERMOSET VS. collars, and other supports), and lightweight cosmetic
THERMOPLASTIC covers for upper and lower limb prostheses.

CONVERSION
CHARTS:
Temperature
Measurement
DECISION-MAKING TOOLS: Durometer Scales of Hardness
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MATERIAL
VARIABLES:
Strength
Density
THE DUROMETER
Durability
Hardness The purpose of a durometer is to identify the hardness of materials—
Stiffness specifically, polymers, elastomers, and rubbers. It helps determine the
Thickness material’s resistance to permanent indentation.
Molding Temperature
Corrosion Resistance
Grindability
The durometer is both a measurement as well as the gauge instrument
Sheet Size used to determine the measurement. Albert Shore defined and developed
Malleability hardness durometer scales—the three most common being Shore 00,
Ductility Shore A, and Shore D. The points on the presser foot of the gauges get
Lamination progressively sharper, from Shore 00 to Shore A to Shore D.
OPEN- vs. CLOSED-
CELL FOAMS
Durometer readings should:
DUROMETER SCALE • Have a minimum thickness of ¼ inch
• Be measured parallel to the surface
MOHS SCALE • Be measured within one second of pressing down with the gauge

THERMOSET VS.
THERMOPLASTIC

CONVERSION
Note: Additional durometer information follows on the next slide.
CHARTS:
Temperature
Measurement
DECISION-MAKING TOOLS: Durometer Scales of Hardness
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MATERIAL Here is a snapshot of how Shore scales overlap when identifying the hardness of various materials.
VARIABLES: All values, ranges, and item examples are approximate and should be used as a general guide only.
Strength
Density
Durability
Hardness
Stiffness
Thickness
Molding Temperature
Corrosion Resistance
Grindability
Sheet Size
Malleability
Ductility
Lamination
OPEN- vs. CLOSED-
CELL FOAMS

DUROMETER SCALE

MOHS SCALE

THERMOSET VS.
THERMOPLASTIC

CONVERSION
CHARTS:
Temperature
Measurement
DECISION-MAKING TOOLS: Mohs Scale
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MATERIAL Mohs Scale of Hardness
VARIABLES:
Strength
The Mohs scale ranks materials—specifically, minerals, Grade/Value Substance
Density gemstones, and metals—on their hardness. 1 – 1.5 Tin, Plastic, Pencil Lead
Durability
Hardness The scale was developed by the German geologist Friedrich 2 Cadmium
Stiffness Mohs. He used a simple guide of scratch resistance to 2.5 – 3 Gold, Silver, Aluminum,
Thickness Copper, Zinc, Brass,
Molding Temperature
determine the hardness grade of each material—that is,
which materials will scratch other materials, and which Bronze
Corrosion Resistance
Grindability materials can get scratched by other materials. The scale is 3.5 Platinum
Sheet Size considered to be relative in nature and somewhat imprecise 4 Iron, Nickel
Malleability yet highly useful.
Ductility 4 – 4.5 Steel, Platinum, Iron
Lamination 5 Zirconium
OPEN- vs. CLOSED-
Referring to the scale to the right, zirconium can be
CELL FOAMS scratched by all the materials that have a higher Mohs grade 5.5 Glass
(such as glass, emerald, and diamond). Zirconium, in turn, 6 Uranium, Titanium
DUROMETER SCALE scratch all the materials with a lower Mohs grade (such as
7 Quartz
nickel, platinum, and silver.)
MOHS SCALE 7.5 – 8 Emerald, Hardened Steel
THERMOSET VS. 8 Topaz, Cubic Zirconia
THERMOPLASTIC 9 Tungsten Carbide
CONVERSION
10 Diamond
Here is an example of a Mohs scale. Many variations of the Mohs scale
CHARTS: exist. The Mohs scale provides grades based on a material’s pure state;
Temperature it assumes no other substances have been added.
Measurement
DECISION-MAKING TOOLS: Thermoset vs. Thermoplastic
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MATERIAL
Plastics tend to fall into one of two categories: thermosetting plastics or thermoplastics. Below is an overview of the two types.
VARIABLES:
Strength
Density
Durability THERMOSET PROCESS THERMOPLASTIC PROCESS
Hardness Chemical bonding takes place. Polymers form No chemical bonding takes place. Polymers
Stiffness
Thickness
an irreversible chemical bond when heated. soften when heated but can be remolded
Molding Temperature The material will not re-melt when heat is and recycled without affecting the material’s
Corrosion Resistance applied. Materials are heat and deformation properties. Materials tend to be high
Grindability resistant, and tend to be strong and brittle. strength, shrink resistant, chemical resistant,
Sheet Size and easily bendable.
Malleability
Ductility
PROS CONS VS. PROS CONS
Lamination Hard crystalline or Generally more
Generally less Somewhat difficult
OPEN- vs. CLOSED- expensive than to surface finish rubbery surfaces expensive than
CELL FOAMS thermoplastic thermoset

DUROMETER SCALE High level of Cannot be remolded Can be remolded Can melt if heated
dimensional stability or reshaped and reshaped to
Good for high-heat Cannot be recycled accommodate
MOHS SCALE
applications; changes or pressure
Resistant to high areas
THERMOSET VS.
THERMOPLASTIC temperatures Recyclable

CONVERSION
CHARTS:
Temperature
Measurement
DECISION-MAKING TOOLS: Temperature Conversion Chart
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MATERIAL
VARIABLES: Use this helpful chart as a quick reference guide.
Strength Working with orthotic and prosthetic materials
Density requires an understanding of the relationship
Durability between Celsius and Fahrenheit temperatures.
Hardness Below are formulas for converting between the two
Stiffness types of temperatures.
Thickness
Molding Temperature
Corrosion Resistance Converting Fahrenheit to Celsius.
Grindability 1. Take the Fahrenheit temperature and subtract 32.
Sheet Size 2. Multiply that number by 5/9 (or .555).
Malleability For example, to convert 95 degrees Fahrenheit to
Ductility Celsius, subtract 32 from 95, which is 63. Multiply 63
Lamination
OPEN- vs. CLOSED-
times .555. The answer is 34.965. The Celsius
CELL FOAMS equivalent is 35.

DUROMETER SCALE Converting Celsius to Fahrenheit.

1. Take the Celsius temperature and multiply by 9/5
MOHS SCALE (or 1.8).
THERMOSET VS.
2. Add 32 to that number.
THERMOPLASTIC For example, to convert 50 degrees Celsius to
Fahrenheit, multiply 50 times 1.8, which is 90. Add
CONVERSION 90 plus 32. The answer is 122. The Fahrenheit
CHARTS: equivalent is 122.
Temperature
Measurement
DECISION-MAKING TOOLS: Measurement Conversion Chart
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MATERIAL
VARIABLES: Use this helpful chart as a quick reference guide when determining the size,
Strength thickness, and density of materials.
Density
Durability
Hardness
Stiffness
Thickness
Molding Temperature
Corrosion Resistance
Grindability
Sheet Size
Malleability
Ductility
Lamination
OPEN- vs. CLOSED-
CELL FOAMS

DUROMETER SCALE

MOHS SCALE

THERMOSET VS.
THERMOPLASTIC

CONVERSION
CHARTS:
Temperature
Measurement
NATURAL MATERIALS
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NATURAL MATERIALS
NATURAL MATERIALS: Overview
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NATURAL MATERIALS OVERVIEW

Materials for
GREATER
Firmness

Materials for
GREATER
Flexibility

This diagram provides an overview of how leather and cork, both natural materials, are categorized in terms of firmness and
flexibility. Leather can be used either as a functional or an accommodative material, depending on what casting techniques and
other materials are used. Cork, a subset of bark tissue, is lightweight, resilient, and shock absorbent. Cork Compounds can be
comprised of liquid latex (a type of rubber), nylon, wood, leather shavings, or other materials. Each combination produces a different
material with different properties and different uses.
NATURAL MATERIALS: Leather
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Leather
Once processed, which includes the steps of Other uses for leather in the O&P field include:
pre-tanning, tanning, and finishing, leather • The lining of straps
provides some highly beneficial properties. • Thigh lacer suspensions
Specifically, it is: • T-straps (correction straps)
• Firm • Patellar suspension cuffs
• Water repellent • Knee disarticulate sockets
• Fast and soft drying • Ankle gauntlets and
• Flexible • Wrist-hand orthoses
• Durable
• Non-compressible and
• Breathable
As with all materials, however, leather does
have its drawbacks. Leather devices can be
more bulky than thermoplastic/synthetic
Because it provides both shock absorption and
devices. And while leather has a low-water
control, leather orthotic devices can help
absorption, it does not hold up well under
control excessive pronatory forces while limiting
repeated soaking.
excessive vertical stress. For custom orthoses,
leather can be used as top and bottom covers.
NATURAL MATERIALS: Leather
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LEATHER BASICS MEASURING LEATHER

• Complex Structure: Corium and
Collagen
• Multi-directional layers of fibers
• Layers
 Upper: Grain
 Bottom: Flesh Side
 Center/Inner Layer: Corium
(Core)
The corium consists of small woven,
twisted fibers that join together.
The collagen molecules are long and
spiral-like. Together, they can produce a
soft, flexible, breathable,
tough material.
The “Bend”: • Measured in square feet and ounces
Considered the best • Thickness: In ounces
part of the hide • One ounce = 1/64th of an inch
because of its
thickness and
1 oz. = .75 irons = 1/64 inch = .41 mm
firmness.
2 oz. = 1.50 irons = 1/32 inch = .78 mm
8 oz. = 6 irons = 1/8 inch = 3.18 mm
Image Source: www.pixabay.com
The hide is cut down the spine to make
16 oz. = 12 irons = 1/4 inch = 6.36 mm
two sides of leather.
NOTE: “Hide” typically refers to the skin
of a large animal while “skin” refers to
the skin of a small animal.

Video: How It’s Made—Leather

NATURAL MATERIALS: Cork
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Cork
Cork is a natural, renewable substance. It is harvested from the bark of cork Oak
trees, which are found primarily in southwestern Europe and northwestern Africa.
The trees are unharmed by the harvesting process.

One of its key components is suberin, a waterproof, waxy substance. This helps
make it buoyant, elastic, and fire retardant. Also noteworthy is that cork has a
honeycomb-like structure that consists largely of empty spaces. Plus, its density
(weight per unit of volume) is one-fourth that of water. These characteristics make
cork a highly effective cushioning material. It is also recognized as being flexible
and highly resilient.

For orthotic devices, cork is often combined with other substances, including
rubber, nylon, and thermoplastics.

Image Source: www.pixabay.com

NATURAL MATERIALS: Cork
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Below are six cork-based products used in manufacturing custom orthotic devices, along with characteristics and properties of
each. This list is a representation of materials available to O&P professionals and is not intended to be comprehensive in
nature.
Birko Cork KorexTM Elasti-CorkTM
Cork granules and nylon blend. Cork granules and rubber blend. Flexible, Cork and rubber blend. Thermoformable.
Porous, lightweight, flexible, strong, durable. Grindable. Resists compression Grindable. Common uses include base
supportive. Available in various forces. Not thermoformable. Common uses layers for foot orthoses and postings. More
thicknesses, as well as soft and hard include accommodations, forefoot rigid than lightweight cork.
densities. Grinds easily. Thermoformable. extensions, and wedges.
Common uses include arch support,
modifications, and repair.

Thermo CorkTM Cushion Cork MulticorkTM

Shredded cork and rubber blend. Strong
and flexible; good for shock absorption.
Thermoformable. Its density makes it a
solid option for those who do not tolerate
rigid devices. Often used when a patient’s
weight is a factor. Thermocork® Lite is a
variation of Thermocork.
Cork and rubber blend. Stiff. Not
thermoformable but easy to grind and skive
(cut off in thin layers or pieces)
to shape. Common uses include
lifts and wedges.
Shredded cork and Ethyl Vinyl Acetate
(EVA) blend. Tough, easy to grind, long
lasting, good shape retention. Common
uses include base layers in foot orthoses
and postings, as well as arch fills, postings,
and heel lifts.
NATURAL MATERIALS: Review
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Visit Quizlet to test your knowledge of Natural Materials.

Click on the link below.

LINK to QUIZLET: NATURAL MATERIALS O&P

Once on the site, click on “Test Your Knowledge: Natural Materials

O&P.” You will see a list of words/terms and their associated
meanings.

1. Give the list a quick review.

2. Choose any or all of the “Study” tools and “Play” tools listed at
the top of the page.
3. Test your knowledge in multiple ways, including flashcards,
formal tests, spelling, and timed games.
4. Note: With the test option, you can re-format in multiple ways
and take as many times as you like.
5. When finished, return to this presentation for more Materials
information.
SYNTHETIC MATERIALS
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SYNTHETIC MATERIALS
SYNTHETIC MATERIALS: Overview
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SYNTHETIC MATERIALS OVERVIEW

Materials for
GREATER
Firmness

Materials for
GREATER
Flexibility

This diagram provides an overview of how synthetic materials are categorized in terms of firmness and flexibility.
Carbon composites and some plastics are rigid materials designed to control function. Plastics can also be semi-rigid,
often constructed by using layers of softer material that are reinforced with more rigid materials. Foams, Ethyl Vinyl
Acetates (EVAs), and gels are softer materials designed to provide a higher degree of accommodation and flexibility. These
materials are more shock absorbent and help minimize pressure. Note: The softness or rigidness of all materials can vary
based on such factors as their thickness or number and types of layers used.
SYNTHETIC MATERIALS: Carbon Composites
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A composite material is a combination of two or more Carbon fiber reinforced plastic/polymer
materials that, while retaining their respective
identities, produce a material with characteristics
different from the individual components.
The plastic material that surrounds fiber reinforcement
is referred to as the matrix. The primary purpose of
fibers in a composite is to provide strength and stiffness,
but the fiber alone can be brittle—for example, glass.
Two basic types of high-strength fiber reinforcements
used in prosthetics are glass and carbon.
Fiberglass reinforced plastic/polymer (FRP) is
commonly referred to as simply fiberglass. It is
comprised of fibers and a polymer matrix. The matrix
contributes to the material’s strength. Reinforcement of
the matrix occurs when the FRP becomes stronger or
more elastic as compared to its original strength and
elasticity.
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(CFRP) occurs when carbon fiber bonds
with a resin system—usually epoxy or
acrylic. The resin works with the carbon
fibers to form a “weave” in a geometric
arrangement. The chemical bond created
by carbon atoms in the resin matrix
produce a material that is strong and stiff.
If the orthotic or prosthetic device needs
to have a strong strength-to-weight ratio,
carbon fiber is a great option.
For prostheses, these composites can be
used for socket reinforcements, transtibial
(TT) and transfemoral (TF) sockets, and
Symes and Knee Disarticulation
Prostheses. For orthotic devices, these
composites work well for people who are
highly active, overweight, or need
specialized orthotic designs.
SYNTHETIC MATERIALS: Carbon Composites
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Reinforced composites should be lightweight, durable, flexible, stiff, and strong under both tension and compression.
Contrast and compare the key characteristics of the materials below.

FIBERGLASS CARBON ARAMID (KEVLAR®)

Heavier than Carbon and Kevlar.
Most economical and most
common composite. Easy to
saturate with resin. Easy to
obtain. Durable and flexible.
Twice as strong under
compression then tension.
Almost as light as Kevlar®. Very
stiff and able to hold its shape
under stress. Strong under
tension and compression.
Carbon fibers create stiffness
and brittleness. Poor resistance
to impact.
Lightest and most expensive
composite. Excellent resistance
to fracture under impact.
Resistant to chemicals; difficult
to saturate with resin. Very poor
in maintaining structure or form
under load. Five times as strong
under compression than tension.

2.56g Density 1.79g Density 1.44g Density

620ksi Tensile Strength 800ksi Tensile Strength 400ksi Tensile Strength

A Carbon-Fiberglass BLEND results in a material A Carbon-Kevlar BLEND results in a material

that is stiff and lightweight (Carbon) as well as that is light and stiff (Carbon) as well as light
flexible and durable (Fiberglass). and impact /torque resistant (Kevlar).
SYNTHETIC MATERIALS: Carbon Composites
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Below is additional information about carbon composites/products and the fiber reinforcement process.
FIBER
All the available strength and
characteristics of a composite fiber
are displayed and produced only
along the length of the fiber.
Fiber comes in two weaves:
unidirectional and bidirectional.
With unidirectional, all fibers are
parallel. In bidirectional, fibers cross
at a 90-degree angle. The weave
and angle used will determine the
material’s strength, flexibility, and
best uses. For example, a
bidirectional carbon-fiber weave
aligned 45 degrees to the line of
progression will produce great
flexibility and could be used in a
device that needs low resistance.
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TL-2100
TL-2100 is a thermoplastic acrylic-
carbon fiber composite laminate. It is
thin, lightweight, strong, heat
adjustable, and available in various
thicknesses and rigidities.
CARBOPLAST®
Carboplast® products use high-
strength carbon and glass fibers. It is
considered to be more flexible than TL
2100. It is available in various
thicknesses and rigidities.
Textiles Metals Chemicals Review
“PRE-PREG”
“Pre-preg” or “pre-preg carbon”
refers to composite fabrics that
have been pre-impregnated by the
manufacturer with thermosetting
curable resin. The resin can be
polyester, epoxy, or some type of
glue. Epoxy is the most common.
The amount and type of resin used
is based on the customer’s
specifications, ensuring the right
amount of fiber to resin. Pre-preg
composites tend to be more
expensive than thermoplastic sheet
materials. It is available in
unidirectional and bidirectional
carbon fiber weaves.
SYNTHETIC MATERIALS: Thermoplastics
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Thermoplastics are plastic materials (polymers) that soften when heated and harden when cooled. They can be remolded and reshaped to accommodate
changes or pressure areas. Thermoplastics provide many benefits because they are lightweight, durable, easy to fabricate, water resistant, easily adjustable,
and recyclable. Typically sold in sheets, thermoplastics are available in many thicknesses, strengths, colors, and finishes.

Following is a list of the types of thermoplastics. Within each Key attributes to consider when
group of plastics, different levels of performance are available. selecting or comparing
• Acrylic thermoplastics include:
• Polyethylene (PE)—typically categorized by their densities: • Sheet size
 Low density (LDPE) • Sheet thickness
 Medium density (MDPE) • Surface type
 High density (HDPE) • Degree of flexibility
 Ultra-high density (UHMWPE) • Degree of rigidity
• Polypropylene (PP)—one of the most rigid thermoplastics • Strength (also referred to as
• Polyvinyl Chloride (PVC) impact strength)
• Co-polymer—a blend of polypropylene and 5% to 10% of • Color and
LDPE • Heating (or forming or molding)
• Polystyrene temperature
• Acrylonitrile Butadiene Styrene (ABS)
• Nylon
• Polyethylene terephthalate glycol-modified (PETG) and
• Proflex/Proflex with Silicone
SYNTHETIC MATERIALS: Thermoplastics
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Below is an overview of thermoplastic materials/products commonly used in the O&P field, along with some of their key attributes.
Polypropylene Thermoplastic Elastomers (TPE) ABS
Rigid, strong, impact and fatigue resistant, Semi-rigid, flexible, durable Strong, stiff, bondable
no moisture absorption, self adhesive
Co-polymer PETG (Vivak®) Acetal
Good formability, rigid yet flexible, Transparent color, tough, hard, easy to bond Strong, stiff, enhanced dimensional stability,
self adhesive and fabricate low moisture absorption

LDPE Polycarbonate Proflex

Soft, flexible, low tensile strength, High impact strength, durable Rubber-like ethylene based, durable,
easy formability flexible
HDPE Acrylic Proflex with Silicone
Durable, flexible, strong, resistant to Very rigid, bondable Very flexible, minimal rigidity, flexible
impact, lightweight
Modified Polyethylene Kydex® Surlyn®
In between co-polymer and LDPE PVC and acrylic blend, rigid, strong Minimal rigidity, flexible, vacuum formable

Orthoplast® Ortholen® SubOrtholen®

Low temperature plastic; once heated, can Tough, corrosion resistant, does not become High molecular weight HDPE,
be molded and applied directly to patient brittle or absorb perspiration flexible, tough polymer, more durable than
Ortholen
SYNTHETIC MATERIALS: Thermoplastics
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Contrast and compare the key properties of the thermoplastic materials/products listed below.
Homopolymer Polypropylene Colyene Co-Polymer PETG (Vivak®)
SURFACE: Smooth SURFACE: Smooth SURFACE: Smooth
FLEXIBILITY: Very little FLEXIBILITY: More flexible than Homopolymer FLEXIBILITY: Minimal
RIGIDITY: Very rigid Polypropylene RIGIDITY: Very rigid
IMPACT STRENGTH: Reasonable to Poor RIGIDITY: Semi-rigid to rigid IMPACT STRENGTH: Very brittle
THICKNESS (IN INCHES): 1/32, 1/16, 3/32, 1/8, IMPACT STRENGTH: Very good THICKNESS (IN INCHES): 1/16, 1/8, 3/16, 1/4, 3/8,
5/32, 3/16, 1/4, 3/8, 1/2, 5/8, 3/4 THICKNESS (IN INCHES): 1/32, 1/16, 3/32, 1/8, 1/2
*HEATING TEMPS: 325 – 3500 F 5/32, 3/16, 1/4, 3/8, 1/2, 5/8, 3/4 *HEATING TEMPS: 250 – 3000 F
COMMON USES IN O&P: Body jackets, ankle foot *HEATING TEMPS: 300 – 3500 F COMMON USES IN O&P: Face masks, check
orthoses (AFOs), definitive sockets COMMON USES IN O&P: Helmets, definitive sockets, burn management, upper limb static
sockets, body jackets, splints orthoses

Low Density Polyethylene (LDPE)
SURFACE: Smooth
FLEXIBILITY: More flexible than Homopolymer
Polypropylene
RIGIDITY: Moderate
IMPACT STRENGTH: Very good
THICKNESS (IN INCHES): 1/32, 1/16, 3/32, 1/8,
5/32, 3/16, 1/4, 3/8, 1/2
*HEATING TEMPS: 325 – 3500 F
COMMON USES IN O&P: Pediatric AFOs, splints,
flexible socket interfaces
Modified Polyethylene
SURFACE: Smooth
FLEXIBILITY: More flexible than Homopolymer
Polypropylene
RIGIDITY: Semi-rigid
IMPACT STRENGTH: Very good
THICKNESS (IN INCHES): 3/32, 1/8, 5/32, 3/16,
1/4, 3/8, 1/2
*HEATING TEMPS: 270 – 3300 F
COMMON USES IN O&P: Spinal orthoses, interim
type of upper and lower limb orthoses
High Density Polyethylene (HDPE)
SURFACE: Smooth
FLEXIBILITY: More flexible than Modified
Polyethylene
RIGIDITY: Semi-rigid
IMPACT STRENGTH: Very good
THICKNESS (IN INCHES): 1/8, 3/16, 1/4
*HEATING TEMPS: 325 – 3500 F
COMMON USES IN O&P: May be used in place of
Polypropylene; tends to crack under stress

* Always check the manufacturer’s recommendations.

SYNTHETIC MATERIALS: Thermoplastics
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Below is a guide showing which thermoplastics are commonly used in O&P devices as they relate to the human body.

HEAD and FACE DEVICES:

NECK and SPINE DEVICES: Polypropylene, Co-polymer, PETG, Polycarbonate
Polypropylene, Co-polymer,
Modified Polyethylene

UPPER BODY DEVICES:

UPPER LIMB DEVICES: Polypropylene, Co-polymer, LDPE, HDPE,
Polypropylene, Co-polymer, LDPE, HDPE, PETG, Modified Polyethylene, Kydex®, ABS
Proflex, Orthoplast®, Proflex with Silicone

LOWER BODY DEVICES:

LOWER LIMB DEVICES: Polypropylene, Co-polymer, LDPE, HDPE,
Polypropylene, Co-polymer, HDPE, TPE, PETG, Modified Polyethylene, Kydex®, ABS
Proflex, Proflex with Silicone

KNEE DEVICES:
Polypropylene, Co-polymer
ANKLE and FOOT DEVICES:
Polypropylene, Co-polymer
HDPE, TPE, Acrylic, Acetal

Image Source: www.pixabay.com

SYNTHETIC MATERIALS: Foams and Gels
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The softer, more supportive and protective devices help to absorb shock, minimize pressure, and improve desirable load-bearing. Devices designed to reach
these goals use foam and gel materials. Firmer foams are supportive in nature while the more flexible/compressible foams are more protective.

Foams have multiple uses with foot orthoses:
• Top layers may consist of soft,
compressible foam, such as neoprene; they
make an orthotic device comfortable and
can extend the life of the material.
• Middle layers often feature polyurethane
foams because they are durable,
cushioning materials.
• Bottom layers can comprise firmer, non-
compressible materials, such as cork,
dense foam, or thin plastic.
Foams are categorized as either open-cell or
closed-cell and are typically polyurethane,
polyethylene, and/or ethyl vinyl acetates
(EVAs).
The softness or rigidness of a material can
vary based on factors, such as its thickness
and the number of layers used. Plastazote®, for
example, is a polyethylene, closed-cell foam
and is considered a “soft” material when a
single layer is used. It would be considered
more rigid if laminated, multiple layers were
used.
A variety of gel elastomers (natural or
synthetic polymers having elastic properties),
such as composite gels, thermoplastic gels,
polyurethane gels, and silicone gels, provides
pressure relief and shock absorption.
Silicones are classified as fluids, elastomers, or
resins. Common uses for silicones in prosthetic
devices include distal end pads in sockets, and
silicone gel inserts. Gel liners conform to the
bony prominence of the residual limb and are
used to provide comfort and protection.
SYNTHETIC MATERIALS: Foams and Gels
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Below is an overview of the types of synthetic materials/foams used in the O&P field.
Within each group, different levels of performance are available.

POLYURETHANE (PU) FOAMS POLYETHYLENE (PE) FOAMS ETHYL VINYL ACETATES (EVAs)

Dense, open-cell, thermosetting
structures that do not conform to the
shape of the foot. PU foams
experience little to no compression
over time.
• PU foams are available in three
groups: flexible, rigid, and
elastomers
• Memory foam, Poron®, Poron®
Medical, and PPT® are examples
of PU foams
• Commonly used in the O&P field
for arch support and high-impact
applications.
Closed-cell, chemically cross-linked
structures that are lightweight,
strong, durable, and excellent shock
and moisture absorbers. Some are
subject to compression with
continued wear.
• PE foams are available in varying
sheet sizes, densities,
thicknesses, and colors
• PE foams are known by such
trade names as Plastazote®,
Pe-Lite®, and Aliplast®
• Commonly used in the O&P field
for total-contact orthoses.
Closed-cell co-polymer (ethylene and
vinyl acetate) structures that are
lightweight, flexible, and shock
absorbent. They tend to compress
over time. They are softer and more
resilient than PE foams.
• EVAs are available in a variety of
durometers and thicknesses
• EVAs are known by such trade
names as Evazote®, Microcel
Puff®, and ThermoSKY®
• Commonly used in the O&P field
for insoles, top and bottom
covers, wedges, cushioning
material, and shell material for
accommodative and functional
orthoses.
SYNTHETIC MATERIALS: Foams and Gels
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Below is an overview of foam materials/products commonly used in the O&P field, along with some of their key attributes and
uses. Note: Many products share the same or similar characteristics and compete under different trade names.

ThermoSKY®: EVA Foam Microcel Puff®: EVA Foam P-CellTM: EVA Foam

Shock absorbing, lightweight, heat formed,
various durometers. Uses: Base, middle
layer, or top cover; prosthetic liners, orthotic
postings, heel lifts, and shoe elevations.
Shock absorbing; heat moldable; various
durometers, colors, and thicknesses; tends
to bottom out when put under pressure- or
sore-producing areas. Uses: Top and
bottom layers in foot orthoses, body jacket
linings, lifts, postings, prosthetic liners, and
cones.
Grindable, soft, heat-moldable, variety of
thicknesses, shock absorbing, durable.
Resistance to “pack-out.” Comparable to
Plastazote. Uses: Cushioning, coverings,
insoles.

Evazote®: EVA Foam Poron® and Poron® Medical PPT®

Various durometers, comfortable, resilient.
Uses: Depending on durometer chosen,
orthotic top cover and base for diabetic and
arthritic patients, molded insoles, distal
pads, shells, shoe elevations.
Polyurethane Foam, Medical Grade
Breathable, odorless, washable, shock
absorbing, very durable, lightweight,
flexible, not heat moldable, grindable.
Similar to PPT. Uses: Custom orthoses,
prefabricated orthoses, prosthetic padding,
cushioning, metatarsal and heel pads.
Commonly used as the middle layer of foot
orthoses.
Polyurethane Foam, Medical Grade
Shock absorbing, resilient, lightweight, does
not compress. Similar to Poron. Uses: Soft
tissue supplement for cushioning, shock Additional materials /
absorption, and friction reduction. Also products continue on
used as self-adhesive components for heel the following slide.
wedges, heel lifts, metatarsal pads and bars,
and longitudinal arch pads.
SYNTHETIC MATERIALS: Foams and Gels
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Below is a continuation of an overview of foam materials/products commonly used in the O&P field, along with some of their key
attributes and uses. Note: Many products share the same or similar characteristics and compete under different trade names.

Nickelplast-S: EVA and Polyethylene Foam Aliplast®: Polyethylene Foam Plastazote® Polyethylene Foam

Tough, tear resistant, variety of durometers,
resists bottoming out, shock absorbing,
resilient and rubbery quality. Uses:
Cushioning, postings, sock liner, PTB liners.
Soft, smooth in appearance, variety of
densities/durometers. Comparable to
Plastazote but the rigid density of the
Aliplast XPE is heavier than the rigid
durometer of Plastazote. Uses: Direct-
molded orthotic fabrication, cushioning,
liner material.
Lightweight, heat moldable, various
densities and durometers, conformable,
grindable. Poor shock absorber. Contours
easily to the foot. Will compress or “bottom
out.” Uses: Top covers in orthoses and AFO
interfaces, base layers in foot orthoses and
light postings. Also used as liners for
prostheses and orthoses.

Pe-Lite®: Expanded
Polyethylene Foam
Lightweight, moisture proof, shock
absorbing, variety of thicknesses, densities,
and durometers. Similar to Plastazote. Uses:
Cushioning, commonly used for sockets,
pads, AFOs, prosthetic liners.
Neoprene: Closed-Cell Rubber Foam
A synthetic polymer resembling rubber.
Medium softness, variety of thicknesses,
great compression resistance. Uses: Top
cover, inlay for soft foot orthoses, full-
length orthotic devices used in athletic and
casual shoes with removable insoles.
Spenco® Closed-Cell Neoprene Foam
Contains nitrogen gas bubbles. Durable,
flexible, compatible with moisture
exposure. Has a nylon top cover. Uses:
Orthotic arch supports, top cover for plastic
orthoses, insoles.
SYNTHETIC MATERIALS: Foams and Gels
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The key information needed to select foam materials includes the durometer, sheet size, composition, molding
temperature, grindability, colors, and uses. Below is an example of how this information is typically presented in an O&P
materials catalog.
Image Source:
www.pixabay.com
SYNTHETIC MATERIALS: Review
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Visit Quizlet to test your knowledge of Synthetic Materials.

Click on the link below.

LINK to QUIZLET: SYNTHETIC MATERIALS O&P

Once on the site, click on “Test Your Knowledge: Synthetic Materials

O&P.” You will see a list of words/terms and their associated
meanings.

1. Give the list a quick review.

2. Choose any or all of the “Study” tools and “Play” tools listed at
the top of the page.
3. Test your knowledge in multiple ways, including flashcards,
formal tests, spelling, and timed games.
4. Note: With the test option, you can re-format in multiple ways
and take as many times as you like.
5. When finished, return to this presentation for more Materials
information.
TEXTILES
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TEXTILES
TEXTILES: Overview
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Textiles have numerous uses within the O&P field. The The “lay-up” process includes:
lamination process for orthoses and prostheses, for 1. Sealing the model (PVA bag, cellulose acetate)
example, involves the saturation of reinforcement textiles 2. Layering the textiles
with a resin. 3. Applying the outer PVA bag
4. Saturating the textiles with resin and hardener under
vacuum
A reinforcement textile is a fabric/fiber, such as 5. Curing
fiberglass, nylon, cotton, Dacron, carbon, and Kevlar, used
to provide strength. The strength of the laminate is
determined by the material properties of the fiber and
the resin. Important properties to consider include:
• Stress Video: How Is Your Prosthesis Made?
• Strain
• Stiffness (Young’s Modulus)
• Ultimate tensile strength (UTS)
• Yield strength
• Brittleness and
• Ductility
TEXTILES: Terms
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t I s …”
“Wha LAY-UP: Materials AND a Process. The combination of all textiles placed in position over the
model. The process of placing successive layers of reinforcing materials in position in the model.

ULTIMATE TENSILE STRENGTH (UTS): The maximum force applied before a fiber breaks.

YOUNG’S MODULUS: The measure of the stiffness of a solid material.

TEXTILES: Nylon, Fibers, Braids, Felt, Velcro
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Below are examples of textiles/products commonly used in the O&P field, along with some of their key attributes and uses.
Perlon® Stockinette
Used for socket laminations, AFOs, KAFOs,
KOs; compatible with all types of resins;
superior elasticity; smooth appearance.
Basalt Braid
Used for composite sockets and AFOs,
plastics reinforcement; tough, durable,
strong, lightweight, superior resin saturation.
Carbon Fiber Braid
Used for strong, lightweight layups,
reinforcement for laminated devices,
prosthetic sockets; lightweight, strong,
conforms to irregular shapes.
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Nyglass Stockinette
Used for sockets that need to be
lightweight and thin, socket laminations,
AFOs, KAFOs, Kos; combines the
lightweight strength of fiberglass with the
elasticity of nylon.
Dacron Straps
Used for arm harnesses and as reinforced
strapping. Strong, durable. Resists
elongation under tension.
Fiberglass Tapes and Sleeves
Used for reinforcement and wrapping
applications to cover small areas or unique
shapes; compatible with polyester, vinyl
ester, and epoxy resins.
Textiles Metals Chemicals Review
Nylon Stockinette
Used for socket laminations—TF and TT;
nylon fibers add durability to artificial limbs
and other orthotic devices.
Dacron Felt
Used in laminations as “base” layer/inner
surface of a lamination, on the outside of
the sockets for lining and padding, around
trim lines; provides extra material inside of
socket for grinding out reliefs without
sacrificing integrity of the reinforcement
material; provides little strength.
Velcro®
As a hook and loop fastener, used for
attaching straps or padding to hard-surface
materials, such as splints and braces.
TEXTILES: Review
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Visit Quizlet to test your knowledge of Textiles.

Click on the link below.

LINK to QUIZLET: TEXTILES O&P

Once on the site, click on “Test Your Knowledge: Textiles O&P.”

You will see a list of words/terms and their associated meanings.

1. Give the list a quick review.

2. Choose any or all of the “Study” tools and “Play” tools listed at
the top of the page.
3. Test your knowledge in multiple ways, including flashcards,
formal tests, spelling, and timed games.
4. Note: With the test option, you can re-format in multiple ways
and take as many times as you like.
5. When finished, return to this presentation for more Materials
information.
METALS
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METALS
METALS: Overview
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Metals are used in the O&P field in many ways: Key attributes to consider when selecting or comparing
• For prosthetic devices, which replace parts of the body metals for O&P devices include:
• For orthotic devices, which augment and/or support parts • Strength—compressive, tensile, and yield
of the body. • Stiffness
• Hardness—can be determined in relative terms through
With the exception of mercury, a liquid element, metals are use of the Mohs scale
solids at room temperature and typically have high melting • Resistance to fatigue
points and high density. They have good electrical and thermal • Density
conductivity. One key characteristic of metals is their ability to • Bio-compatibility
be deformed without immediately breaking. • Resistance to corrosion
• Ease of fabrication and
Alternatives to metals include composite materials because • Cost
they are strong, lightweight and often less expensive than some
metals. Examples of specific considerations include:
• The amount of weight the device has to support—For
lower-body prostheses and orthoses, the metals need to
have a good resistance to fatigue.
Video: Physical Properties of Metals: • The control needed—For devices that need more control,
Tensile Strength, Impact Strength, lower density is important.
Malleability, Ductility, Melting Point • Fatigue—Devices for the lower extremity must be resistant
to repetitive loading.
METALS: Malleability vs. Ductility
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Metals are often evaluated based on their malleability and ductility.

MALLEABILITY DUCTILITY

 The property of a metal that  The property of a metal that

BE enables it to be hammered, bent, enables it to stretch without CA
CA N STR N BE
I N TO pressed, or rolled into sheets damage
TE N
BEA EETS
SH
without breaking VS. INT ETCHE
OW D
 Provides information about a IRE
S
 Provides information about a metal’s tension strength
metal’s compressive strength
 Measures how much strain a metal
 Measures how much pressure the can withstand before failing
metal can withstand without
breaking  Ductile metals include but are not
limited to gold, silver, platinum,
 Malleable metals include but are copper, and iron.
not limited to gold, silver,
aluminum, and copper.
METALS: Steel, Aluminum, Titanium, Copper
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Below is an overview of four metals commonly used in the O&P field.

STAINLESS STEEL ALUMINUM TITANIUM COPPER

• A steel alloy that
contains 12% or more
of chromium
• Martensitic stainless
steel is used in the
O&P field because it
can be hardened by a
heat treatment
• High degree of
stiffness
• High resistance to
corrosion
Typical applications: Joints,
support uprights, washers,
fasteners, rivets, screws
• The most abundant
element in the earth’s
crust
• Lightweight, highly
conductive, non-toxic
• Can be easily
machined
• Higher strength-to-
weight ratio than steel
• Low resistance to
fatigue
• Susceptible to
corrosion from body
fluids
Typical applications:
Strengthening supports
and other structures,
rivets, screws
• Ti-6AI-4v most
common alloy used
• Stronger than
aluminum
• Comparable in
strength of stainless
steel but 60% lighter
• Very high resistance to
corrosion
• Difficult to fabricate
• More expensive than
aluminum and
stainless steel
Typical applications:
replacement joints,
artificial limbs, implants,
adapters, connectors,
rotating bases
• Pure copper is soft;
two alloys are bronze
and brass
• Copper alloys become
stronger and more
ductile as temperature
goes down
• Malleable and ductile
• Good resistance to
atmospheric corrosion
• More dense than
aluminum
• One of the best
electrical conductors
of all metals
Typical applications: rivets,
screws, burrs
METALS: Review
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Visit Quizlet to test your knowledge of Metals.

Click on the link below.

LINK to QUIZLET: METALS O&P

Once on the site, click on “Test Your Knowledge: Metals O&P.”

You will see a list of words/terms and their associated meanings.

1. Give the list a quick review.

2. Choose any or all of the “Study” tools and “Play” tools listed at
the top of the page.
3. Test your knowledge in multiple ways, including flashcards,
formal tests, spelling, and timed games.
4. Note: With the test option, you can re-format in multiple ways
and take as many times as you like.
5. When finished, return to this presentation for more Materials
information.
CHEMICALS
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CHEMICALS
CHEMICALS: Styrene, Acetone, Toluene, MEK
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When choosing chemicals, weigh the advantages and disadvantage of each, and try to use the least
hazardous whenever possible. Below is an overview of commonly used chemicals in the O&P field.
CHEMICAL USES for O&P
STYRENE Used to make plastics, rubbers, and resins.
A colorless liquid consisting of carbon Also used as a filler or thinner and reactive
and hydrogen; can have an odor.
cross-linker to polyester resins.
Primarily a synthetic chemical.
Used as a solvent for plastics and synthetic
ACETONE fibers, a thinner to polyester and epoxy
A colorless, volatile liquid with a mint- resins, and to synthesize Bisphenol A
like odor. Moderately aggressive. (BPA), a chemical found in hard plastics
and epoxy resins.
TOLUENE Used as a solvent. Resembles Benzene, a
A colorless liquid with an aromatic colorless and highly flammable liquid with
Benzene-like odor. a sweet smell.
Used as a thinner for polyester and epoxy
METHYL ETHYL KETONE (MEK) resins. Used when an evaporation slower
A colorless liquid with a sharp, sweet than acetone is desired. Water soluble.
alcohol-like odor. Also known as
Butanone.
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Textiles Metals Chemicals Review
DANGERS
Regarded as a hazardous material and possibly a
carcinogen. Possible irritation to the eyes, nose,
respiratory system, central nervous system, liver,
reproductive system.
Slight toxicity in normal use. Highly flammable.
Not regarded as a carcinogen. Possible irritation to
the eyes, nose, throat, respiratory system, central
nervous system. Considered safer and less toxic
than toluene solvents.
Harmful vapor/fumes. Flammable. Possible
irritation to the eyes, nose, respiratory system,
central nervous system, liver, kidneys.
Harmful vapors/fumes. Flammable. Possible
irritation to the eyes, nose, respiratory system,
skin, central nervous system, mucous membranes.
CHEMICALS: Resins
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Below is an overview of three types of thermosetting resins commonly used in the O&P field.
Attributes to consider when comparing and selecting resins to use in any given situation include ease of use, cost,
degree of possible toxicity, strength and flexibility, degree of adhesion, shrinkage, cure time, and shelf life.

POLYESTER RESINS
Thermosetting unsaturated synthetic resins combined with hardeners. Contains approximately 60% polyester and 40% styrene. Fractures easily;
lacks durability: best suited for lighter-weight objects. Compatible only with fiberglass materials—limited use for lamination, seaming, and
repairing. Not water resistant. Poor adhesion. High shrinkage. Shorter cure time than epoxy resins. Less expensive than epoxy resins.

VS.
ACRYLIC RESINS
Produced from methyl methacrylate (MMA) and dissolved polymethyl methacrylate (PMMA). Hardness can be adjusted for various applications.
More water resistant than polyester resins. Bonds to core materials better than polyester resins. Shrinks less than polyester resins on curing.
More expensive than polyester resins; less expensive than epoxy resins.

EPOXY RESINS
VS.
Thermosetting polymer combined with hardeners. Also known as a polyepoxide. High tension strength. Greater flexibility than polyester resins.
Better than polyester resins for high-strength bonding. Does not contain styrene. Reinforces glass and carbon materials. Very little shrinkage. Able
to bond dissimilar and already cured material. Longer cure time than polyester resins. More expensive than acrylic resins and polyester resins.
CHEMICALS: Dust Particles
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DUST PARTICLES IN THE WORKPLACE
Working with carbon fiber and
metals adds dust particles
and other abrasive elements
into the air.
They are by-products of the
manufacturing process.
Sanding and grinding create more
fine dust than cutting.
Depending on the material,
particle size and concentration,
and exposure time, dust can cause
a variety of health problems.
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www.pixabay.com
Natural Synthetic
Materials Materials
GOALS:
Reduce dust infiltration
for health reasons
and
to minimize/eliminate the
possibility of combustion.
A cloud of dust can cause
an explosion.
Even materials that do not burn in
larger pieces (such as aluminum or
iron) can explode in dust form,
given the proper conditions.
Textiles Metals Chemicals Review
The risks associated with working
around dust particles can be
managed/minimized.
SOLUTIONS:
Proper ventilation and air-
purifying systems
Proper and frequent training for
best practices
Proper collection systems
Use of masks and respirators,
especially when cutting, grinding,
and sanding materials
CHEMICALS: Protection
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TYPES OF PROTECTION
O D ADVICE! FROM CHEMICALS AND DUST:
GO the end
of
o ughly at ng and
nd s t ho r
eati • Rubber or plastic gloves and sleeves protect
Wash ha ty and prior to
vi against heat and abrasion. Consider a heat
each acti
.
drinking n a l protecti
ve insulating terrycloth or leather glove.
pe rs o
s e a p p ropriate nd clothing to
U )a
ent (PPE he face. •
equipm nds, eyes, and t Simple protective glasses can protect against flying
ha
protect w o rk clothin
g dust and small particles. A face shield provides
a n y t
/replace aminated or we additional coverage and may be necessary when
Remove n t
omes co uids.
that bec able liq dealing with caustic fluids.
fl am m
from d
p e r l y v entilate
a pro •
Work in nt. Proper ventilation can dramatically control the
me
environ D ata Sheets amount of dust and other particles in and around
afe ty
aterial S f a work area.
Keep M ailable in case o wide
(MSDS)
av
T h e y p rovid a first
e
ncies . uding
emerge formation, incl ents, and • A filtration mask/device may be necessary when
in m
range of ent, reactive ele
tm working close to the source of dust or chemical.
aid trea g measures.
tin
fire figh
Image Source:
www.pixabay.com
CHEMICALS: Review
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Visit Quizlet to test your knowledge of Chemicals.

Click on the link below.

LINK to QUIZLET: CHEMICALS O&P

Once on the site, click on “Test Your Knowledge: Chemicals O&P.”

You will see a list of words/terms and their associated meanings.

1. Give the list a quick review.

2. Choose any or all of the “Study” tools and “Play” tools listed at
the top of the page.
3. Test your knowledge in multiple ways, including flashcards,
formal tests, spelling, and timed games.
4. Note: With the test option, you can re-format in multiple ways
and take as many times as you like.
5. When finished, return to this presentation for more Materials
information.
REVIEW
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REVIEW
Use the following Review Section to test and apply your knowledge.
The self-assessment included in this section features multiple-choice
questions that cover subject matter from the entire presentation.

1. Read the question.

2. Click on the answer that most accurately reflects the correct
response.
3. If the answer is correct, continue the self-assessment by clicking
on the “RETURN TO THE QUIZ” link. Then, click on the forward
arrow.
4. If the answer is incorrect, the correct answer will be provided.
Continue the self-assessment by clicking on the forward arrow.
5. Use the back arrow anytime to re-visit previous questions.
REVIEW
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1. Which one of the following represents an example of a soft material

that might be used in the fabrication of a foot orthosis?

Carbon fiber

Polypropylene

Open-cell polyurethane foam

Polyester resins
REVIEW
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2. The process wherein polymers form an irreversible chemical bond

when heated and the material cannot be remolded or reshaped is called:

Thermoplastic

Thermoset

Young’s modulus

Pre-preg
REVIEW
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3. The property of a metal that enables it to be hammered,

bent, pressed, or rolled into sheets without breaking is:

Ductility

Grindability

Malleability

Durability
REVIEW
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4. Plastazote, Pe-Lite, and Aliplast are examples of:

Polyester resins

Carbon fiber reinforced plastics

Open-cell thermosetting foams

Polyethylene foams
REVIEW
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5. Acetone and toluene are both:

Chemical solvents

Steel alloys

Polyester resins

Lamination materials
REVIEW
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6. Foamed thermoplastics are formed by forcing nitrogen or

some other gas into the plastic during heating. They can be:

Malleable or ductile

Open-cell or closed-cell

Natural or synthetic

Dense or durable
REVIEW
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7. Density can be calculated:

As the load divided by deformation

Using the Mohs scale

Using a durometer

As the material’s weight per unit of volume

REVIEW
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8. The tool that helps determine a material’s

resistance to permanent indentation is the:

Mohs scale

Iron

Durometer

Laminator
REVIEW
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9. The process of placing successive layers of reinforcing

materials in position in the model is called:

Young’s modulus

Lay-up

Pre-preg

Thermosetting
REVIEW
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10. In the lamination process, reinforcement textiles

are fabric / fibers used to provide:

strength

comfort

weight

tension
REVIEW
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ATTRIBUTIONS
Aliplast is a registered trademark of Alimed.
Carboplast is a registered trademark of Aetrex Worldwide, Inc.
Dacron is a registered trademark of DuPont.
ElastiCork is a registered trademark of Acor Orthopaedic, Inc.
Evazote is a registered trademark of Zotefoams, Inc.
Kevlar is a registered trademark of DuPont.
Kydex is a registered trademark of Kydex LLC.
Microcel Puff is a registered trademark of Acor Orthopaedic, Inc.
Multicork is a registered trademark of Acor Orthopaedic, Inc.
Ortholen is a registered trademark of Teufel Orthopedic /
Wilhelm Julius Teufel.
Perlon is a registered trademark of Perlon-Monofil GMBH
PPT is a registered trademark of Langer Biomechanics Group, Inc.
P-Cell is a registered trademark of Acor Orthopaedic, Inc.
Pe-Lite is a registered trademark of Fillauer, LLC.
Plastazote is a registered trademark of Zotefoams, Inc.
Poron is a registered trademark of Rogers Corporation.
Spenco is a registered trademark of Spenco Medical Corporation.
SubOrtholen is a registered trademark of Teufel Orthopedic.
Surlyn is a registered trademark of DuPont.
Thermo Cork is a registered trademark of Aetrex Worldwide, Inc.
ThermoSKY is a registered trademark Aetrex Worldwide, Inc.
Velcro is a registered trademark of Velcro Industries B.V.
VIVAK is a registered trademark of Sheffield Plastics Inc.

Although the authoring institution of this educational resource has made every effort to ensure that the information presented is correct, the institution
assumes no liability to any party for any loss, damage, or disruption caused by errors or omissions.

Images used from Pixabay are released into the Public Domain under Creative Commons CC0. Images used from Wikimedia Commons are released into
the Public Domain by the copyright holder. Except where otherwise noted (Pixabay and Wikimedia Commons images), t his work by Oklahoma State
University Institute of Technology is licensed under the Creative Commons Attribution 4.0 International License. To view a copy of this license, click on the
following link: Creative Commons Licenses 4.0.