Monday, April 22, 2024

carbon fiber floor reaction AFOs – summary of responses

Leigh Davis

Hello! Thank you all for your thoughtful responses! You all gave me a lot
to think about!

As one respondent said, “I really think that these kids need dynamic
response orthoses. We wouldn’t put active amputees in stiffer and stiffer
SACH feet, so why do we attempt a similar approach to our orthotic
clients??” Such a good point. Perhaps the posterior dynamic element
designs are the answer.

For this patient, I did move forward with a super rigid design from Kinetic
Research. 3 weeks in and so far so good – we’ll see how it goes.

Here is a list of all the responses:

Specific designs and c-fab recommendations. Number of recommendations in

– Kinetic Research (11)

– Phat (6)

– Custom Composites (6)

– Motion Unlimited (4)

– Otto Bock Carbon ankle 7 (4)

– Fab Tech (3)

– Freedom Fabrication (3)

– PolyPro Texas Turbos (2)

– Dynamic Bracing Solutions

– Ortho Baltic

– Coyote Dynamic strut braces

– Jim Skardutos C-fab

– BPM Fabrication

– Custom toe off/blue rocker

– Shadow Brace by Becker

Other recommendations:

– Articulated with Becker joints and fabricated by Motion Unlimited

– If you’re not making it out of prepreg carbon stop while you’re
ahead. If so run a flat foot plate from mid foot forward with a minimum of
3 layers 2 bi and 1 uni sandwiched between increase # of uniti increase
stillness build in toe spring to reduce volume in shoe.

– Consider increasing/extending the A-P length around ankle/failure
points: these contours often do not need to follow patient’s anatomy.
Extend these as far anterior and/or posterior as footwear permits.

– consider using pre preg composites to manufacture your AFO’s, not
lamination. You get a much strong, lighter and thinner result

– Curbell Plastics

– Talk to the makers of Rush Feet

– Reinforce with Ultra g brace (carbon only)

– 1/4″ ProComp carbon infused polypropylene

Again, thank you so much! Looking forward to continuing the conversation,

Leigh Davis

> —–Original Message—–
> >From: Leigh Davis
> >Sent: Jan 24, 2017 2:45 PM
> >To: [email protected]
> >Subject: [OANDP-L] carbon fiber floor reaction AFOs
> >
> >Hello!
> >I am in the middle of a project making floor reaction AFOs for an active
> 13
> >year old male with Spina Bifida. He has been wearing floor reactions for
> >many years, and has broken an impressive number of them. Now that he’s
> 110
> >lbs and 5″2″, I’m trying to switch him to a carbon fiber construction.
> >We made him a set here that he walked great in, but he broke them at the
> >ankle, forefoot (even though the forefoot is sulcus length) and at the
> heel
> >within 1 week.
> >
> >I still feel this is the right design for him, but I’m looking for some
> >advice with either of the following:
> >
> > – What lay up do you recommend if we were to try again at our in house
> > lab?
> > – Is there a central fab you’ve had success with for laminated floor
> > reaction AFOs?
> >
> >
> >Thank you for your time and assistance!
> >
> >Leigh Davis, CPO
> >
> > ********************
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> >
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