AFO NEURO SWING H2O

AFO

NEURO SWING H2O System Ankle Joint

The NEURO SWING H2O system ankle joint consists of a carbon fibre reinforced joint case, a seawater-resistant stainless steel screwing and spring units in special spring unit sleeves. Because of the system joint’s properties, the technique for producing an AFO (ankle foot orthosis) with NEURO SWING H2O differs from the Joint and Anchor Lamination Technique. Its system anchors are especially designed for this waterproof system ankle joint.

This online tutorial describes the basic production of an AFO with the NEURO SWING H2O system ankle joint. You will find the joint assembly in the Extras tutorial Joint Assembly NEURO SWING H2O.

 Mounting the Assembly/Lamination Dummy

Step 1/1

Mount the system joint by using the assembly/lamination dummy and in accordance to the exploded view drawing. When laminating, the assembly/lamination dummy serves as placeholder for the system joint's joint case.
Note: You can find exploded view drawings in our product catalogue System Joints and Articulated System Side Bars.

 Bending the System Stirrups/Anchors

Step 1/9

Mark the lower edge of the assembly/lamination dummy on the system stirrup and the upper edge on the system anchor. Everything above or below this line must not be bent, as these areas are part of the system joint later.

Step 2/9

Clamp the system stirrup into a vice with plain jaws to bend it. Pay attention to the marking to avoid a subsequent deformation of the joint areas and to be able to bend very close to the joint.

Step 3/9

Adapt the system stirrup to the shape of the model. Bend the system stirrup neck with a bending iron. Only bend in one direction.
Note: Do not use a hammer and do not heat the material.

Step 4/9

Remove the system stirrup from the vice and check the distance from the system stirrup to the model.

Step 5/9

Adapt the system stirrup to the shape of the model. Bend the lower part of the system stirrup with a bending iron. Only bend in one direction.
Note: Do not use a hammer and do not heat the material.
Check the distance to the model.

Step 6/9

Adapt the system stirrup to the shape of the model. Bend the system stirrup foot with a bending iron. Only bend in one direction.
Note: Do not use a hammer and do not heat the material.
Check the distance to the model.

Step 7/9

Clamp the system anchor into a vice with plain jaws to bend it. Pay attention to the marking to avoid a subsequent deformation of this area which is adhered to the joint later. While bending, please consider the applicable bending radii and use proper tools (bending iron with round edges).
Note: You will find information on bending radii in the manual for System Side Bars and System Anchors.

Step 8/9

Check the distance from system anchor and stirrup to the positive cast. Please make sure to have enough space left for the reinforcing profile and the reinforcement layers in order to avoid later strains to the laminate. Thus, the joint areas stay parallel.

Step 9/9

Grind the system stirrup and the system anchor. Always grind in direction of rolling. Remove all notches from bending and avoid sharp edges.
Note: System ankle joints with dorsiflexion stop, which can be adjusted by filing, should always be mounted in their pre-assembled neutral position without changing the dorsiflexion stop.

 Reinforcing and Laminating the AFO

Step 1/5

Use a profile core and produce the system string. Reinforce as usual.
You do not need a shaping dummy.
Important! Please consider the processing instructions and the safety data sheets for our epoxy resin and hardener.

Step 2/5

Use a sharp knife to remove the thin laminate layer over the dummy. Remove the screws.

Step 3/5

Carefully lever the dummy out of the laminate at the marked spot (arrow). Make sure not to damage the joint areas of the system stirrup in the process.

Step 4/5

Mark the cutting edges by following the previously modified edge of the later orthosis. For optimally integrating the system joint and gaining the maximum possible bearing surface at the foot piece, only remove as much of the laminate as necessary and as little as possible.

Step 5/5

Remove all laminate parts which are no longer necessary. Then, you can remove the orthosis parts from the model.

 Tempering and Grinding the AFO

Step 1/4

Clean all the joint areas as well as the system stirrup before you temper the parts of the orthosis. Heat all wax residues with a hot air blower (1) and blow
the liquefied insulating wax out of the hollows (2). Remove all residues with a cloth (3). Remove the PVA film tube as well.

Step 2/4

Temper all parts of the orthosis before you grind them. Place the orthosis parts into a cold oven and heat it up slowly. When tempered, the parts of the orthosis are stable and can be worked in the best possible way.
Important! Also note the processing instructions for epoxy resin.

Step 3/4

Grind the edges of the orthosis parts (e.g. with an angle grinder). However, it is essential to avoid predetermined breaking points in the metal! Also make sure that the flexible area of the foot piece is even (without brinks).
Note: Even after tempering, you can still work aramid fibres with sharp scissors.

Step 4/4

In order to remove all possibly caused notches, remove remaining resin residues from the system stirrup with a sharp knife and polish the stirrup subsequently (e.g. with a marbling tool).

 Mounting the System Joint

Step 1/1

Continue the assembly of the joint as described in the online tutorial
“Joint Assembly NEURO SWING H2O”.