Special Work Steps when Producing a KAFO with a NEURO HiTRONIC

Mount the system string on the model.

Locate a suitable position on the lower leg shell of the model where you can attach the lamination dummy for the controller. Use CA activator spray as basis and adhere the dummy with medium-viscous fast-acting adhesive to the dummy for the padding material. Note: comply with the safety data sheet for the fast-acting adhesive.

Mark the spot where the connection cable will later be led through the laminate. A suitable tool for this is a drift pin. In the case of an anterior tibial shell, the front hole in the shaping dummy serves as a marking aid (see picture). In the case of a posterior shell, use the back hole for orientation.

Insert one end of the lamination dummy for the connection cable into the lamination dummy for the controller.

Use CA activator spray as basis for the spot marked in step 3. Adhere the other end of the lamination dummy for the connection cable to this spot with medium-viscous fast-acting adhesive.
Important! Use the entire length of the lamination dummy for the connection cable!

Secure the part of the lamination dummy for the connection cable that is still loose with medium-viscous fast-acting adhesive. Use CA activator spray as basis.

Position the lamination dummy for the cable length compensation so that it touches the lamination dummy for the connection cable. The lamination dummy for the cable length compensation is used to create space for any excess cable length. Use CA activator spray as basis and adhere the lamination dummy for the cable length compensation with medium-viscous fast-acting adhesive to the dummy for the padding material.

Remove the system string. If the model is still wet, insulate it with compression film. Then, pull a PA reinforcement stocking and a PVA film tube over the model. The lamination dummies for the controller and the connection cable are now located under the PVA film tube and are thus part of the model.

Reinforce the orthosis shells. Make sure that the reinforcement layers end close to the lamination dummy for the controller and do not wrinkle. Reinforce strongly above and below the lamination dummy. This additional material is needed for attaching the thread insert. You can find more information on this in the tutorial Joint Assembly NEURO HiTRONIC.

Cover all dummies with the last layer.

This production technique is specifically adapted to our epoxy resin and hardener.
Important! Please note the processing instructions and the safety data sheet for the epoxy resin and hardener. Precisely stick to the mixture ratio and thoroughly mix resin and hardener.

Allow the fibres to soak thoroughly when casting and rub out any excess resin. Place the shaping dummy on the assembly/lamination dummy and secure it.

Leave the model overnight (at least 10 hours) under vacuum at room temperature.
Important! Follow the processing instructions for the epoxy resin here as well.

Cut the system joints free. An arrow is milled on the assembly/lamination dummy to indicate where to lever out.

For this step, the laminate in the area of the lamination dummy for the controller remains closed. Saw the orthosis shells and remove them from the model. The lamination dummy for the controller and the lamination dummy for the cable length compensation remain on the model for the time being.

Clean the orthosis shells and remove the PVA film tube. Temper the orthosis shells.
Important! Follow the processing instructions for the epoxy resin here as well.

Grind the orthosis shells. At the location where the controller will be mounted, remove the laminate along the edges formed by the lamination dummy for the controller. Be careful when removing the laminate. Slowly approach the ideal fit and periodically check whether the controller already fits into the opening.

Now, expose the connecting point for the connection cable.

Mount the system joints as described in the instructions for use and the corresponding online tutorial.