KAFO: LoadShifter Lamination

Our technicians explain our technique for laminating a LoadShifter KAFO.

[@Onam52]

I regularly refer to your videos which are great source of professional tips and techniques. This video is no exception, a big Thank you. Also please guide how to secure the Knee Joints with the Carbon Laminated Shells, are they to be riveted or glued. Please explain both the procedures.

[@AdvancedOrthopedic]

We rivet them after lamination. We want them to be removable so they can be reaired. We use rivets, but screws can also be used. I don't think glue is a good option. I'm glad you like the videos. Good luck!

[@MrAlvarezErick]

@@AdvancedOrthopedic t

[@FernandoTipan-tt4ju]

Que precio tiene este Kafo con este material

[@muhammadhood6287]

Amazing work....Mah field Orthotics and Prosthetics 💕

[@jellyandme]

What difference does drying out the PV bag make on the final product? Does water evaporating mess up the finish like wet plaster in a check socket? Thanks

[@AdvancedOrthopedic]

No, water evaporation doesn't have any effect I'm aware of. The bag does need to be moist to apply to the leg, but not for lamination.

[@jellyandme]

@@AdvancedOrthopedic So, why do it? Surely drying it out just adds an extra step to the process?

[@davidfricker3258]

He should not be using flag as a rag. It is like using a sacred book to start a fire for a BBQ.

[@powerWithinUs4055]

Thought that same thing, inexcusable. Irreverent, unnecessary. Offensive.

[@NudgingCharlie13]

Is there a second part to this? Very interesting. So much work goes into making this.

[@ehsanabdulqar4537]

I am disabled. I want a prosthesis. Can you send an address?

[@EdwinJalando-on]

sana.begyn.ko.ng artificial legs

[@DeanLeatherman]

What I don't understand is why the final flow of epoxy is so labored. Fiberglass boat manufacturers are able to draw resin the entire length of a boat without assisting it. Also has there been any load validation testing or even load specification for this part? Just on the face of it is seems wildly over layered for its purpose... is it supposed to be bullet and shrapnel proof? A normal tube component this size with half the layers could support literally tons of dynamic loading. One other point, the 3M 77 is really going to hamper your resin penetration as used under the layers, it is not needed as a crutch to hold the part. I do understand the need to mend the cuts, this is always done with resin and taped until hardened in the fiberglass industry. This will also hold the firm in the post processes. In other industries the final flow is done at the inflection cure point of the resin mend used for bonding to keep from creating a shearing weakness. A review of how this is accomplished in other industries would be very beneficial to how this techniques are being applied to this assembly. I also have many question about the use of the PVA layers. As I understand their normal usage is to provide smoothness to surface finishes. Why are there so many layers buried so deeply in the cross section? Their smoothing presence in embedded layers alone will severely weaken the twist shear of the assembly leading to delamination issues, in addition the penetration of the resin is observable. Has a cross section analysis of resin penetration ever been done? However since it is so over designed in regard to the amount of layers of carbon used, this will not be a problem. If it ever was a problem... this was most certainly an expensive solution. Other methods can be used to provide shock strength to the part if that is what PVA layers they are for... is this some kind of overthought compression bearing. It might be useful for a catastrophic failure mechanism, which by definition would render the assembly useless after such a load was induced. Again just on the face of it, you could probably cut the cost of this assembly in half just with simple process changes from other resin processing industries. Once again a review of other industry techniques would be useful in a overall review of this process.

[@AdvancedOrthopedic]

Hello Dean, I do not pretend to be an expert on the materials science. Perhaps we don't need all the material, but we want to be sure it doesn't fail, thus bullet proof. This was a video my tech did and he did OK. I've heard about how Super 77 does impede saturation but it worked out good enough. We make very few orthoses with carbon fiber. Thanks for your thoughts.

[@JackMW1992]

A large part of the reason the lay ups have to be so thick is that it doesn't stay a tube. Once you cut away almost half the material, shape becomes much weaker. I've seen prosthetic sockets with thicker laminations get cracked from repeated high stresses a human can impart over years. The additional weight is minimal, and the real cost to these devices is the time, not the materials. The cost of a few extra layers pales in comparison to the expense of a redo or an injured patient. The 2 pva bags are used to contain the resin. The nylon under the first on only acts as an air wick to seal it to the model. There are studies in our field that have shown laying different fibers like carbon and nyglass reduce the brittle characteristics of these laminations. No idea why our resins are so thick but they always are that hard to spread. The point about the 3M impeeding resin uptake is interesting though.

[@MultiRajkrishna]

Hello sir...can u upload the next part of this video..

[@amjedsenpai]

The first layer that will contact the skin directly should be biocompatibility material. Carbon fiber can cause irritation to the skin. How did you solve this problem?

[@kanecol2401]

@@herbtender910 if done correctly your carbon prosthetic should not be heavy. A good fitting socket even if heavy should still feel light.

[@sradanbiri7430]

Perfect 👍👏👏👏

[@straightmoon334]

I am a student working on the outskirts and I have a weakness in taking please explain how to take

[@saifulsyazwanmohffadzil1650]

Hi Can I have some advice on the PVA bag for AFO lamination. I try to laminate tamarack AFO but I have problem with PVA bag as lot of wrinkle appear especially around the ankle. I try changing several measurement to make it more fitted but it does not seem to be working. I really look forward for your advice for the PVA bag. thank you

[@AdvancedOrthopedic]

You cannot get the PVA bag to fit perfectly on AFO casts. You need to pull the wrinkles, usually above the ankle and in the arch area, to the front of the cast and out of your finish trimlines. It only needs to be smooth in the part of the lamination you will actually use. I hope this helps. Kevin

[@muhammadnouman91]

Advanced Orthopedic Designs one more idea is after you done lamination process pull the pva bag and apply tap that will help keep the pva bag wrinkle less around the ankle joint..... good luck .... by the way nice video

[@russrusselson2136]

why do they put the nylon layers between the carbon, it seems like that would result in mutiple pieces being separate

[@samecken]

Kinda late here but from what I understand separating the carbon with nyglass strengthens the device and keeps it light.

[@keyup2626]

Fantastic job, I've had many pairs made for me over a lot of years and have never seen them made, to cool. Thank you for making this video.

[@neeleshkumarahirwar2775]

keyup2626

[@thornwarbler]

Great to watch you lads in action i hope there is going to be a part 2

[@noumanwazir1053]

Part 2 ????????

[@marcelocarvalho552]

Acrylic resin?

[@周炳强]

Where can I buy the pva bag ?thanks

[@ehsanabdulqar4537]

Hi

[@Aerofreak-fz8be]

Hi! When you vacuum to prepare for the lay-up, what type of plastic bag do you use and where can you purchase them? Thanks!

[@AdvancedOrthopedic]

We use extra long PVA bags purchased from Otto Bock. You can also custom make your own.

[@thedailystruggles3721]

Hello I've been watching your videos I currently wear a kafo on my left leg and was curious how much light a carbon kafo would be than the plastic one I have currently?

[@AdvancedOrthopedic]

There is not muck weight difference typically. It would depend on how your current KAFO is made. You could probably lose a pound to a pound and a half in overall weight.

[@hadiqayasoob5206]

why did you laminate KAFO? i mean molding would be easier????

[@karl-christianlippert8405]

Hadiqa Yasoob why would molding the kafo be better?

[@周炳强]

What kind of plastic bags you use?

[@AdvancedOrthopedic]

We use high density polyethylene plastic bags. Low density PE can melt. Heavy duty bags are preferable.

[@malkoojawan1271]

I need job i know that work

[@muhammetturgut7865]

hi dear im mechanical engineering student and this is mu homework can you write şehit tüpe of galass

[@AdvancedOrthopedic]

+Muhammet Turgut Hello, I'm going to need a better translation. Not sure what you're asking.

[@muhammetturgut7865]

+Advanced Orthopedic Designs 😄😄 turkish keyboard problem sorry I m asking about which composite material did you use?(particularly which tüpe of glass). I hope this is better now.Thank you.

[@muhammetturgut7865]

+Muhammet Turgut type of glass

[@AdvancedOrthopedic]

+Muhammet Turgut It is Nyglass stockinette

[@ivanodecicco4494]

Great! What kind of resin used ?

[@AdvancedOrthopedic]

+Ivano De Cicco We typically use Epoxacryl, but I don't think it matters much.

[@robinmasih5978]

Hi

[@aparnasahoo8755]

great work

[@AdvancedOrthopedic]

Thank you!