Lamination Dummies NEURO MATIC/NEURO TRONIC

Lamination Dummies

for NEURO MATIC and NEURO TRONIC System Knee Joints

When producing an orthosis with the automatic knee joint system NEURO MATIC, it is possible to prepare a potential conversion into a NEURO TRONIC knee joint system. So-called lamination dummies serve as placeholder for different system components. In this online tutorial, you will find step-by-step instructions for the use of the lamination dummies.

 

Click here for an online tutorial of the complete production of an orthosis with NEURO MATIC/NEURO TRONIC in Joint Lamination Technique.

 

 Attaching the Lamination Dummies

Step 1/5

For the NEURO MATIC knee joint system, have the following lamination dummies (green) ready:

  • the lamination dummy for the cable cover guidance and the cable cover conduit.

For the NEURO TRONIC knee joint system, have the following lamination dummies ready:

  • the lamination dummy for the controller and the solenoid connection cable (blue).
  • for p-Motion, also the pressure sensor placing aid, the lamination dummy for the pressure sensor cable and the lamination dummy for the pressure sensor solder joint (white).

Step 2/5

Attach the dummies as shown in the picture on the dummy for the padding material. For NEURO MATIC, the lamination dummy for the cable cover guidance (green) and the cable cover conduit (without fig.). For NEURO TRONIC, the lamination dummy for the controller and the one for the solenoid connection cable (blue) and for p-Motion the lamination dummy for the pressure sensor cable (blue) and the lamination dummy for the pressure sensor solder joint (white). Please take into account that the cable should run close to the system joint, but still must have enough distance to the posterior spring duct of the system ankle joint later.

Step 3/5

For p-Motion, place the pressure sensor placing aid (white) on an even surface at the posterior area of the heel of the foot piece. Choose a position where a later connection to the pressure sensor solder joint is possible. Mark the position on the foot piece. Remove the placing aid.

Step 4/5

If you would like to keep all converting options open, attach all dummies. You can also use the lamination dummy for the controller as shaping dummy if you are producing an orthosis with the NEURO MATIC system knee joint and maybe would like to convert it into a NEURO TRONIC later on.

Step 5/5

Use the activator spray as basis and fix the required dummies with some medium viscous fast-acting adhesive to the dummy for the padding material.
Note: Mind the safety data sheet when using fast-acting adhesive.

 Reinforcing the Orthosis

Step 1/6

If necessary, insulate the positive cast. Then, pull over a PA reinforcement stocking and a PVA film tube so that all dummies attached are under the base film. Start with the reinforcement.

Step 2/6

Reinforce as usual until the mounting of the system string. After attaching the lamination dummy for the controller (blue) to the dummy for the padding material, make sure that the reinforcement layers also fit closely to the dummy and do not wrinkle.

Step 3/6

For a NEURO MATIC knee joint system, make a small cut into the reinforcement layers at the lamination dummy for the cable cover guidance (green) in direction of the joint retainer. The base film must not be damaged!

Step 4/6

Mount the NEURO MATIC/NEURO TRONIC assembly/lamination dummy and for the NEURO MATIC knee joint system, stick the cable cover conduit (green) filled with insulating wax into the intended opening of the assembly/lamination dummy. If you do not use the cable cover conduit, fill the opening with insulating wax.

Step 5/6

Through the reinforcement layers, the cable cover conduit for the NEURO MATIC knee joint system now reaches the lamination dummy for the cable cover guidance. Continue reinforcing as usual. With the last layer, cover all dummies (also the one for the controller).

Step 6/6

Continue laminating as usual. Note the time of hardening of the epoxy resin.
Important! Please note the processing instructions and the safety data sheet for our epoxy resin and hardener. Precisely stick to the mixture ratio and thoroughly mix resin and hardener.

 Cutting the Orthosis

Step 1/3

Cut free the system joints as usual. On the NEURO MATIC/NEURO TRONIC assembly/lamination dummy an arrow is milled in to show where you should lever out the assembly/lamination dummy.

Step 2/3

Saw out the orthosis shells as usual.

Step 3/3

Remove the orthosis parts from the model. The dummies attached to the dummy for the padding material at the beginning of this production technique must remain on the model and are not to be removed!

 Tempering the Orthosis

Step 1/3

Clean the orthosis shells and remove the films. Then, temper the orthosis parts as usual.
Important! Also note the processing instructions for epoxy resin.

Step 2/3

At a NEURO MATIC knee joint system, you need an opening for the cable cover. Drill a hole from below which leads to the bulge (green) caused by the dummy for the cable cover guidance. In order for the cable cover to be able to move freely in it, remove the laminate at the drilling hole as shown.

Step 3/3

Remove the laminate above the bulge (blue) caused by the lamination dummy for the controller.

 Preparing the Sensor Placement

Step 1/8

The following pictures show how to place the pressure sensor when using p-Motion with (left) and without (right) height compensation at a NEURO TRONIC knee joint system.

Step 2/8

Mark the correct position of the sensor under the foot piece by using the pressure sensor placing aid. The sensor should be positioned centrically in the rear third of the heel.
with: Consider a possible leg length discrepancy by using an appropriate height compensation/a proper sole.

Step 3/8

Drill an 8mm hole into the lateral outer rim. This hole is meant for the sensor cable.

Step 4/8

with: Drill out the sensor area with a Forstner bit (30mm diameter).
without: Roughen the surface of the sensor area to provide better grip for the adhesive AGOMET® F330.
Note: Mind the safety data sheet when using the adhesive AGOMET® F330.

Step 5/8

with: Do not place the sensor directly on the sole construction material. The EVA material is flexible and would allow small movements in the sensor area.
without: Mix the adhesive AGOMET® F330 with the hardener powder (mixture ratio 100:3). Spread it onto the roughened surface.

Step 6/8

with: Fill the drilled out sensor area with a filling compound. Spare the drilling for the cable (e.g. by using a greased drill shank).
without: Create a flat surface by pressing an appropriate material, e.g. polyethylene (PE), on the adhesive.
Important! Do not remove the placing aid until the adhesive has completely hardened.

Step 7/8

with: Grind the hardened filling compound in order to straighten it. Take care not to remove any surrounding material.
without: If necessary, redrill the hole and mark the position for placing the sensor again.

Step 8/8

with: The hardened filling compound now serves as an even surface to attach the pressure sensor to. The opening for putting the cable through is maintained thanks to the used placeholder.
without: Grind the edge that was created during pressing. Make sure not to damage the flat surface.