Manual Stream Manufacturing

Orthotic Fabrication Technique

At Canada Orthomedix, we use the Manual Stream fabrication technique, a traditional method in use for over 16 years. The production of orthotics is a multi-step process with detailed, intricate cast correction, orthotic fabrication, and modifications prescribed by the practitioner for treatment.

Manufacturing Process

Once we receive a prescription, we produce orthotics after moving them through five manufacturing, and two evaluation, stations.

STATION 1:             The prescription following a bio mechanical examination (with appropriate measurements) studied.

STATION 2:             A 5D scanner digitally scans the negative cast impression and we use the Ortho Manager software to design  and modify for correction and manufacturing

STATION 3:            A 3D scan of the patient’s foot is emailed to the lab and used by Ortho Manager to digitally modify the cast  for correction and manufacturing

STATION 4:             The thermoplastic piece is cut out by the milling machine, according to design

STATION 5:             We then ground the shell to remove any excess, and smoothed for comfort. We then add any additions, extensions and postings at the shell station, as requested.

STATION 6:             We then add and polish the selected top cover

STATION 7:             Our technical director reviews the prescription and examines the orthotics device quality application.

Materials Used

POLYPROPYLENE:   A thermoplastic material that is heated at high temperature and moulded. It is lightweight & versatile, with high impact strength. It is extremely resistant to breakage, and range from quite flexible/compliant to relatively rigid.

SUBORTHOLENE:    A thermoplastic material that is extremely rigid, for control of motion. Recommended for UCBL orthotics.

PLASTAZOTE:          A lightweight, closed-cell polyethylene foam material used as a top cover for diabetic orthotics or as a moulding layer where total contact is desired; non-toxic and unaffected by common acids.

PORON (PPT):         A frothed, open-cell urethane sheet that is breathable, odourless, washable and non- sensitizing. It absorbs more shock than any other material, and is used in sports orthotics or as a full protection material for the diabetic or arthritic patient.

EVA:                        EVA is heat-mouldable so it can conform perfectly to every foot. It has a greater rubber-like (Ethylene vinyl acetate) quality, and is softer and more comfortable. Ideal for patients with sensitive feet, or who suffer from arthritis.

All orthotic shells are made at 1mm, 2mm, or 3mm thickness.

We take pride in the quality of our orthotic devices and the benefits they provide your patients. Only qualified technicians manufacture our orthotic devices.

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