Thanks to those who replied. The original queary is stated below, with the responses following:
I would appreciate some advice on an inexpensive/cost effective lamination layup protocol, taking into account cost of materials, and weight and activity level of amputee.
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This is something I came up with a few years ago. I can say that we are not using as much material as this calls for. How much less I do not know right of hand. I work at the patient care facility and don’t get over to the fabrication facility as often as I probably should. I have recieved feedback already that these lay-ups would build “bomb proof sockets”. Thats ok, because I don’t ever want someone having a socket that I delivered, break. LAMINATION LAY-UP-STANDARDS
Two stage lamination
LIGHT CLASS (up to 165 lb. or low activity to 200 lb.)
Acrylic socket LIGHT CLASS
A: FIRST LAM
1 felt
2 layers nyglass
1 layer carbon
* if using a 3 or 4 prong adapter
reinforce distal end with 2 layers carbon sheet material
B: SECOND LAM (after OWW block or pronged adapter gunked on)
Carbon tape to reinforce the prongs or the OWW block
4 layers nyglass
Carbon acrylic socket and frames for flex sockets LIGHT CLASS
A: FIRST LAM
1 layer felt
1 layer carbon
* if using 3 or 4 prong adapter
reinforce distal end with 2 layers carbon sheet material
B: SECOND LAM (after OWW block or pronged adapter, gunked on
Carbon tape to reinforce the prongs or the OWW block
2 layers nyglass
1 layer carbon
2 layers nyglass (optional for pigmented finish) LAMINATION LAY-UP-STANDARDS
Two stage lamination
MEDIUM CLASS (up to 250 lb.)
Acrylic socket MEDIUM CLASS
A: FIRST LAM
1 felt
2 layers nyglass
1 layer carbon
2 layers nyglass
* if using 3 or 4 prong adapter
reinforce distal end with 3 layers carbon sheet material
B: SECOND LAM (after OWW block or pronged adapter, gunked on
Carbon tape to reinforce the prongs or the OWW block
4 layers nyglass
Carbon acrylic socket & frames for flex sockets MEDIUM CLASS
A: FIRST LAM
1 layer felt
2 layers carbon
* if using 3 or 4 prong adapter- reinforce distal end with 2 layers carbon sheet material
B: SECOND LAM (after OWW block or pronged adapter, gunked on
Carbon tape to reinforce the prongs or the OWW block
2 layers nyglass
1 layer carbon
2 layers nyglass (optional for pigmented finish) LAMINATION LAY-UP-STANDARDS
Two stage lamination
HEAVY CLASS (over 250 lb.)
Carbon acrylic socket & frames for flex sockets HEAVY CLASS
A: FIRST LAM
1 layer felt
2 layers carbon
2 layers nyglass
* use only 3 prong adapter and reinforce
distal end with 2 layers carbon sheet material
B: SECOND LAM (after 3-prong adapter, gunked on)
2 layers nyglass
2 layers carbon
2 layers nyglass (optional for a pigmented finish)
H/D carbon acrylic socket over 250 lbs.
HEAVY CLASS carbon socket lay-up except
increase total carbon layers to 5.
**The problem with your question is inexpensive/cost effective. We laminate our temporary limbs out of nylon (10 layers for BK and 12 for AK) and polyester resin. This is really cheap, but adds a lot of weight to the leg. The weight is good because the patient’s limb receives more excercise and when the definitive leg is made, the leg will be more lightweight. For our definitive legs, we use 4 layers of nyglass, 1 carbon fiber, 1 fiberglass matt around the proximal brim only, and four more layers of nyglass. This is probably more expensive than you wish, but I’ve never had one crack or break in my 8 years of experience.
