Reusable Casting Reusable Casting Apparatus Apparatus

for Custom Orthoticsfor Custom Orthotics

Group Members:Ryan Cook, Keegan Compton,

Michelle Sauer

Advisors:Matt Moore - Sole Supports Inc.

Dr. Paul King - Vanderbilt University

Sole Supports Inc.Sole Supports Inc.• MASS Position Theory

– Maximum Arch Subtalar Supination

• Full Contact Orthotic

Red- Neutral Position

Gray- MASS Position

Casting TechniqueCasting 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

ProblemProblem• 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 WorkPrevious 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 ObjectivesProject Objectives• Find a Reusable Material

– Maintain Sole Supports Inc. Casting Method

– Cost Effective– Environmentally Friendly– Easily returns to original

shape

Potential SolutionsPotential 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 3DIdea #1: Pin-Art 3D• Pros:

– Easily reusable– Instant reset: flip and go

again!– Utilized by other orthotic

companies! (neutral)

• Cons:– Only utilizes the z-direction– Resolution requirements

would mean very small pins!

Idea #2: Latex/Memory Idea #2: Latex/Memory FoamFoam

• Using memory foam to capture the footprint and latex as the exterior barrier, a catch 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

Idea #3: Shape Memory Idea #3: Shape Memory AlloyAlloy

• Metal that returns to its original shape when acted upon by temperature

• Pros

- Easily returns to original shape

• Cons

- Expensive

- Temperature Range

Completed WorkCompleted 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 More Completed WorkWork

• Researched Shape Memory Alloys

• Researched Pin Art

• Researched Memory Foam

• Met with Dr. Sung to discuss

- biomaterials

- memory shape polymers

Current WorkCurrent Work

• Researching Cost and Feasibility of Materials

• Developing Website

• Begin Planning

Prototype Design

Future WorkFuture Work• Purchase Materials

• Finalize Prototype Design

• Begin Building/Testing of Prototype