Reusable Casting Apparatus for Custom Orthotics Group Members: Ryan Cook, Keegan Compton, Michelle Sauer Advisors: Matt Moore - Sole Supports Inc. Dr. Paul King - Vanderbilt University

Sole Supports Inc. MASS Position Theory – Maximum Arch Subtalar Supination Full Contact Orthotic Red- Neutral Position Gray- MASS Position

Casting Technique Foam Casting Box –Captures foot in three dimensions Foot Introduced Sequentially –Heel to Forefoot –Mimics gait cycle Floor Used as Plane of Reference –Heel, fifth and first metatarsal head brought down to floor Semi-weight bearing –Maintains maximum arch supination

Problem Sole Supports Inc. pays over $500,000 annually to ship foam casting boxes to their clients Foam casting box is not reusable and poses a threat to the environment

Previous Work 2006 Vanderbilt Senior Design Project –Low Cost Scanner Sole Supports Inc. has tried other materials and casting techniques –Want fresh eyes to look at the problem

Project Objectives Find a Reusable Material –Maintain Sole Supports Inc. Casting Method –Cost Effective –Environmentally Friendly –Easily returns to original shape

Potential Solutions Mud-like substances Modeling Clay Play-Doh Pinart 3-D Impressions Gels (ceramic powders and solvents) Mattress Material (Memory Foam) Temperature Dependent Materials

Idea #1: Pin-Art 3D Advantages: –Easily reusable –Instant reset: flip and go again! –Utilized by other orthotic companies! (neutral)

Problems with Pin-Art 3D Only utilizes the z-direction Resolution requirements would mean very small pins Imaging –Holes between pins would lead to problems –Solution would require shortening the gaps –Time Cost

Idea #2: Shape Memory Alloy Metal that returns to its original shape when acted upon by temperature Advantages –Easily returns to original shape Problems –Expensive (Custom Made) –Temperature Range ( ºC)

Idea #3: Latex/Memory Foam Using memory foam to capture the footprint and latex as the exterior barrier, a check valve will allow air to escape as pressure is added to the top, but not allow it to come back in. Pros: –Hooking it back to an air hose makes it easily resetable and reusable Cons: –Three point test for coplanar accuracy may not be as easy to take with latex exterior

Initial Memory Foam Testing Initial tests to measure certain properties –Retraction time –Temperature Hot –Heating lamp, hot plate, heating pad Cold –Cold pack, freezer, ice bucket –Applied Force & Time of Applied Force –Shape of Material –Addition of Liquid –Foam Density May not even need latex exterior if the properties of the foam allow us to safely interact with it above glass transition temperature

Memory Foam (beige) would have an airtight latex barrier (dotted line) so that the air from the foam would only escape through the check valve (black hole). The dimensions planned currently are the same as the dimensions of the current pink foam used (36.5 cm x 15 cm x 6 cm).

Completed Work Met with Matt Moore at Sole Supports Inc. Toured Sole Supports Inc. Received instruction in Sole Supports Inc. casting techniques Learned limitations of current casting process Established goals for project NCIIA proposal

More Completed Work Researched Shape Memory Alloys Researched Pin Art Researched Memory Foam Met with Dr. Sung to Discuss –Biomaterials –Memory shape polymers Researched Material Costs Ordered Memory Foam Established Timeline the Rest of the Semester

Current Work Memory Foam Testing Setting Dates for Testing at Sole Supports Developing Website

Future Work Build Workable Prototype Create Standard for Comparison using Sole Supports Current Methods Test Prototype at Sole Supports