Special Work Steps when Producing an AFO with a NEURO HiSWING R+ System Ankle Joint

Mount the system string on the model.

Mind the correct position when placing the lamination dummy for the controller. The arrows must point upwards so that the controller can be installed correctly later.

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 lamination dummy with medium-viscous fast-acting adhesive to the dummy for the padding material.

Note: please note the safety data sheet for the fast-acting adhesive.

Mark the spot where the connection cable will later be led through the laminate. This spot is about 10cm above the axis screw of the system joint and, depending on the joint version, located either left or right beside the system string.

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 4. 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 online tutorial Joint Assembly NEURO HiSWING R+.

Cover all lamination 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 laminating and rub out any excess resin.
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.

Use an oscillating saw to saw along the cutting edges in order to remove the orthosis parts from the model. You can see the recommended saw blade in the picture. Thus, you can saw very close to the system joint without damaging it.

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 joint according to the instructions for use of the NEURO HiSWING R+. You can find illustrated step-by-step-instructions in the online tutorial Joint Assembly NEURO HiSWING R+.