CASTING & FORMING
Transcript of CASTING & FORMING
CASTING & FORMINGPUR Foams ......................................................................................... 14
OKM Foams ......................................................................................... 18
Cast Bandages .................................................................................. 22
Casting Tools ...................................................................................... 24
Casting Boxes ..................................................................................... 25
Cast Cutters ........................................................................................ 28
Casting Interfaces .............................................................................. 30
Casting & Forming
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asti op pur rigid FoamsPUR rigid foams with a wide range of applications in prosthetics and orthotics. Solutions for every application for the production of moulds and appliances with bulk densities of approx. 100-700Kg/m³.
Asti OP® H200 PU FoamFoam for deep drawn models and cosmetic coverings in prosthesis construction.
Density approx. 220Kg/m³, foaming factor approx. 5.0.
Mixing ratio: A:B = 100:100 parts by weight.
Code Size
TK1556 4.6Kg
TK1558 865g
Asti OP® H300 PU FoamFoam for deep drawn models and cosmetic coverings in prosthesis construction.
Density approx. 320Kg/m³, foaming factor approx. 3.5.
Mixing ratio: A:B = 100:100 parts by weight.
Code Size
TK1560 4.6Kg
TK1562 865g
Asti OP® H100 PU FoamVery light foam.
Density approx. 90Kg/m³, foaming factor approx. 12.0.
Mixing ratio: A:B = 100:110 parts by weight.
Code Size
TK1552 4.6Kg
TK1554 865g
Asti OP® H500 PU FoamLast foam for orthopaedic footwear. This material is nailable.
Density approx. 540Kg/m³, foaming factor approx. 2.0.
Mixing ratio: A:B = 100:100 parts by weight.
Code Size
TK1566 4.6Kg
TK1568 865g
TK1570 9.32Kg
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Asti OP® H700 PU FoamUse for manufacturing very high mechanically stressed positive moulds and models, e.g. shoe lasts and tip additions. This material is nailable.
Density approx. 640Kg/m³, foaming factor approx. 1.7.
Mixing ratio: A:B = 100:100 parts by weight.
Code Size
TK1572 4.6Kg
TK1574 865g
TK1576 9.32Kg
Asti OP® Component BFor all Asti OP rigid foams.
Code Size
TK1546 4.6Kg
TK1548 865g
TK1550 9.32Kg
asti op pur rigid Foams
Asti S PUR-Flexible FoamOpen-cell flexible foam for the manufacture of larger individual paddings such as seats and arm supports. Density approx. 60Kg/m³, foaming factor approx. 15.
The fabricator can use the mixing ratio (in parts by weight) to adjust the Shore A hardness of the part to be foamed.
Mixing ratio:
A:B = 100:50 = Standard adjustmentA:B = 100:42 = Soft adjustmentA:B = 100:58 = Firm adjustment
Asti S should be mechanically stirred. Asti S is sensitive to cold and should not be stored at temperatures below 15°C. Shake thoroughly before use.
Code Description Size
TK1540 Asti S Component A 4.6Kg
TK1542 Asti S Component B 2.3Kg
TK1544 Asti S Component C 500g
AlgecastThe Algecast system is a two-part casting (foam & hardener) resin which is mixed together with a wooden spatula before pouring into the mould.
Expansion is equal to 1.7 times.
Code Description Size
SF5310 Algecast 1.1kg
SF5312 Algecast 11.1kg
SF5318 Release Agent 0.86kg
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AstiTech® 150 PU FoamFor the manufacture of forefoot replacement, flexible foam insoles, custom shoe bedding, seats and individual paddings.
Density approx. 200Kg/m³, foaming factor approx. 5.3.
Mixing ration: A:B = 100:50 parts by weight.
Code Size
TK1596 2.5Kg
TK1594 865g
AstiTech® 300 PU FoamFor the manufacture of forefoot replacement, flexible foam insoles, custom shoe bedding and individual paddings.
Density approx. 280Kg/m³, foaming factor approx. 3.8.
Mixing ration: A:B = 100:50 parts by weight.
Code Size
TK1600 2.5Kg
TK1598 865g
AstiTech® 500 PU FoamFor the manufacture of forefoot replacement, flexible foam insoles, custom shoe bedding, seat shells and individual paddings.
Density approx. 510Kg/m³, foaming factor approx. 2.1.
Mixing ration: A:B = 100:50 parts by weight.
Code Size
TK1504 2.5Kg
TK1502 865g
astitech pu FoamsThis open-cell, rub-resistant flexible foam has very high resilience for the manufacture of various padded parts. The Shore A hardness of the final product can be adjusted by the fabricator by pre-mixing different A components in the desired ratio.
AstiTech® Component BFor all AstiTech flexible foams. The B component is sensitive to cold and should not be stored at temperature below 15°C.
Code Size
TK1610 2.5Kg
TK1608 865g
TK1606 433g
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alphaplast pur rigid FoamsAlphaPlast allows for optimal processing time, which enables adequate time from stirring to filling the mould. The formed parts do not shrink and have a very high heat distortion point.
AlphaPlast® H200 PU FoamFor stump embedding to convert the casting resin stump sleeve into a thick walled fitted part. Can also be used for hard compensations not subject to high stress, especially for greater length discrepancies.
Mixing ration: A:B = 100:100 parts by weight.
Code Size
TK1580 4.6Kg
TK1578 865g
AlphaPlast® H300 PU FoamFor smaller highly stressed parts such as short leg compensations.
Mixing ration: A:B = 100:100 parts by weight.
Code Size
TK1584 4.6Kg
TK1572 865g
AlphaPlast® H700 PU FoamImpact and nail resistant rigid foam, especially for orthopaedic shoe lasts and shoe forms as well as positive moulds in the entire orthopaedic range.
Mixing ration: A:B = 100:100 parts by weight.
Code Size
TK1588 4.6Kg
TK1586 865g
AlphaPlast® Component BFor all AlphaPlast rigid foams.
Code Size
TK1592 4.6Kg
TK1590 865g
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OKM Elax High absorption PU for insoles
OKM ELAX for PU insoles ideally suited to diabetic patients, poly arthritic patients and for patients who require substantial off-loading.
This material can also used for the manufacture of prostheses and insoles for toe amputations (in prostheses for patients with Chopart’s and Lis franc’s amputations, the fore-foot can be integrated into the insole or prosthesis).
Characteristics:
● Thanks to its expansion, this material is 50% lighter than other PUs used in insoles. ● Resistant to wear and tear. ● Allows an integral forefoot to be constructed into the insole.
Product 2kg 5kg 25kg
OKM ELAX LG3033 LG3035 LG3037
OKM ISO 180 LG3039 LG3041 LG3043
OKM DurRigid PU for lasts
Creates non-expansive, extremely hard polyurethane, developed for the manufacture of made-to-measure moulds for insoles and shoes and Chopart prosthesis etc.
● Corrections and reductions can be made using a grinding wheel. ● Additions may be made, where necessary, with plaster or mastic. ● Allows the application of staples and studs.
With the incorporation of OKM Micro F additive, moulds are lighter and easier to modify. Before filling the mould, OKM Desmold L must be applied so that the mould can be turned out correctly.
Product 2kg 5kg 25kg
OKM DUR LG3051 LG3053 LG3057
OKM Micro F LG3059
OKM Desmold L LG3029
OKM ISO 110 LG3045 LG3047 LG3049
OKM Foam 200/300PU for making prosthesesBoth systems (200 and 300) have similar characteristics - they allow expansive polyurethane to be obtained and they have been conceived for the manufacture of prostheses in orthopaedics.
This polyurethane is obtained by mixing OKM Foam 200 or 300 with OKM ISO 110.
Before filling the mould, OKM Desmold L must be applied so that the mould can be turned out correctly.
● Rapid hardening. ● Easy to sand. ● Adheres well. ● Lighter than either wood or plaster.
Product 2kg 5kg 25kg
OKM Foam 200 LG3075 LG3029 LG3079
OKM Foam 300 LG3081 LG3083 LG3085
OKM ISO 110 LG3045 LG3047 LG3049
OKM Desmold L LG3029
okm pu Foams
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Two systems with similar characteristics and applications with which an expansive polyurethane can be obtained for filling patient moulds (mainly corset moulds). Both products should be mixed with OKM ISO110.
● 80 - 90% lighter than conventional plaster moulds. ● Additions can be made using plaster. ● The polyurethane hardens in just a few minutes.
Before filling the mould, OKM DESMOLD L must be applied.
OKM 80/120PU for filling large corset moulds
Product 2kg 5kg 25kg
OKM Foam 80 LG3087 LG3089
OKM Foam 120 LG3091 LG3093 LG3095
OKM ISO 110 LG3045 LG3047 LG3049
OKM Desmold L LG3029
okm pu Foams
OKM CopyFlexible PU for copying prosthetic fittingsNon-expansive system that allows prosthetic fittings common in orthopaedics to be reproduced, without creating undue problems for the patient.
Use a mixture of OKM COPY with OKM ISO 170. Apply a layer of OKM Desmold F so that the mould can be turned out correctly.
● As this is a non-expansive PU, a faithful copy of the fitting can be obtained. ● Allows lamination previous to fitting the PVA cover.
Product 1 kg 1.5 kg 2 KG 5kg 25kg
OKM COPY LG3097
OKM ISO 170 LG3013 LG3015 LG3017
OKM Desmold F LG3027
OKM Flexfoam 80/110PU For making seatsPatients with disabilities, scoliosis and deformities with limited mobility require a correct seating posture in order to avoid excessive pressure, minimising the appearance of ulcers and sores, thus improving the patient’s quality of life.
● Allows filling to take place in various phases. ● Choice of colours and finishes. ● Adaptability and comfort. ● OKM Flex paint seals the unit and hides irregularities.
OKM Flexfoam 80 is normally used for children, OKM Flexfoam 110 for older children.
With OKM paint, the seat can be painted to achieve a suitable finish. This paint has been specifically developed for this PU.
Product 1.5 kg 2 kg 5 kg 25kg
OKM Flexfoam 80 LG3001 LG3003 LG3005
OKM Flexfoam 100 LG3007 LG3009 LG3011
OKM ISO 120 LG3019 LG3021 LG3023
OKM Desmold F LG3027
OKM Isolate C LG3031
OKM Flexpaint LG3025
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Code Size Measurements
SX1130 XXS 35-41cm
SX1131 XS 41-47cm
SX1132 Small 46-53cm
SX1133 Medium 51-59cm
SX1134 Large 55-63cm
SX1135 X-Large 58-67cm
SX1136 XX-Large 61-71cm
OKM Knee OrthosisThis model is recommended for the following pathologies:
● Knee prosthesis postsurgical treatment ● Ligament Injuries ● Kneecap fractures ● Shinbone fractures
Code Description
SX1210 Rigid Foam 170
SX1211 Rigid Foam 300
SX1212 Rigid Foam 500
SX1213 Rigid Foam 700
SX1214 Rigid Foam 900
SX1215 Rigid Foam 1100
SX1216 Soft Foam 300
SX1217 Soft Foam 500
SX1218 Soft Foam 700
SX1219 Soft Foam 900
SX1220 Soft Foam 1100
OKM Foam ResinsPolyurethane foams for use with OKM.
OKM is an immobilisation system which combines rigidity and comfort, utilising the combined properties of polyurethane foam and elastic 100% cotton cloth. The application process lasts less than 7 minutes, with the finished orthosis completely functional within 15 minutes.
Thanks to its zip system the patient can remove the orthosis to take care of the personal hygiene, move forward the rehabilitation exercises, monitoring the progress of the pathology and so on. The zip can be locked to avoid the removal of the orthosis by the patient.
okm system
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OKM Dorsal - Lumber CorsetThis model is recommended for the following pathologies:
● Dorsal and lumbar spine fractures ● Osteoporosis ● Rheumatism ● Espondilolisis ● Postsurgical scoliosis treatment
Code Size Measurements
SX1090 XXS 55-64cm
SX1091 XS 64-75cm
SX1092 Small 73-84cm
SX1093 Medium 82-95cm
SX1094 Large 91-108cm
SX1095 X-Large 100-115cm
SX1096 XX-Large 109-125cm
Code Size Measurements
SX1150 XXXS 23-27cm
SX1151 XXS 26-30cm
SX1152 XS 29-33cm
SX1153 Small 30-35cm
SX1154 Medium 34-39cm
SX1155 Large 37-42cm
SX1156 X-Large 40-46cm
SX1157 XX-Large 43-50cm
OKM Accessories & Essentials
Code Description
SX1231 OKM Portable Mixer
SX1234 OKM Small Roller
SX1235 OKM Large Roller
SX1236 OKM Plastic Mixer
SX1242 OKM Steel Adaptor for Mixer
More OKM accessories are available, please contact us for further information.
OKM Orthosis BootThis model is recommended for the following pathologies:
● Shinbone and fibula fracture ● Aquiles pathologies ● Paralysis ● Joint rheumatism ● Ankle ligament injuries
okm system
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Revive Synthetic Cast TapeAlternative to POP bandages for taking casts or for general orthopaedic use, Revive Cast is a synthetic tape which is manufactured from knitted fibreglass or polyester with water activated polyurethane resin. The fabric used in preparation of the roll is flexible in all directions which makes it very comfortable to use.
Code Size Colour
SW1600 5cm x 4m White
SW1605 7.5cm x 4m White
SW1610 10cm x 4m White
SW1615 12.5cm x 4m White
Code Size Colour
SW1650 5cm x 4m White
SW1655 7.5cm x 4m White
SW1660 10cm x 4m White
SW1665 12.5cm x 4m White
Code Size Colour
SW1701 5cm x 4m White
SW1706 7.5cm x 4m White
SW1711 10cm x 4m White
SW1716 12.5cm x 4m White
Polyester
Semi-Rigid Polyester
Fibreglass
Gefix POP BandagesPremium grade POP bandages for casting. Specially treated plaster spreads uniformly. Thick creamy texture when wet which allows for a smooth cast finish.
Code Size Per case
SF5208 7.5cm x 3m 80
SF5209 10cm x 3m 60
SF5211 15cm x 3m 40
SF5212 20cm x 3m 30
SF5218 15cm x 25m 1
Multicast POP BandagesMulticast POP Bandages combine quick setting, high grade plaster with a conformable and stable interlocked weave. The bandage has minimum plaster loss whilst the rich creamy texture allows easy handling.
These POP bandages are competitively priced for heavy users and those on tight budgets.
Code Size Per case
SF5262 7.5 x 2.7m 12
SF5264 10cm x 2.7m 12
SF5266 15cm x 2.7m 12
SF5268 20cm x 2.7m 12
synthetic cast tape
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Revive Under-PadFor use with synthetic tapes when used for orthopaedic use. This product does not require any additional cotton bandage due to the elasticity and the protective properties of the Under-Pad.
Revive Under-Pad has excellent wicking properties, absorbing moisture to prevent skin irritation. The material is also water resistant.
Code Size Colour
SW1750 5cm x 4m White
SW1751 7.5cm x 4m White
SW1752 10cm x 4m White
SW1753 12.5cm x 4m White
SW1754 15cm x 4m White
pop Bandages
STS Casting SocksIntended for use in moulding the foot for the purpose of making a shoe last (casting). It can also be used for duplicating (copying) an orthotic device for the foot, ankle or lower leg.
STS Casting Socks are made from a stretchy, fibreglass knit, which are impregnated with a water curable polyurethane resin. By exposing the material to water, a chemical reaction is initiated which causes the tubular moulding material in the STS Socks to become rigid.
Finished moulds or lasts made from the material are strong, lightweight and replicate the limb with great accuracy. The clinician using STS Copy Socks will find their use cleaner and quicker than traditional methods based on Plaster of Paris.
Slipper SockCode Size (UK)
SG1062 2 - 4
SG1063 5 - 8
SG1064 9 - 11
SG1065 12 - 14
Ankle SockCode Size (UK)
SG1030 2 - 4
SG1034 9 - 11
SG1036 12 - 14
Bermuda SockCode Size (UK)
SG1071 5 - 8
SG1072 9 - 11
SG1073 12 - 14
Sundries for Copy SocksCode Description
SG1050 STS Leg Lifter (with case)
SG1052 Plastic protective cutting strips
SG1055 Protective bags (100 per box)
Bemuda Sock Ankle Sock
Slipper Sock
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Plaster Cast ScissorsHigh quality professional plaster scissors that are notched and rust proof.
Code SizeLA4618 22cm
Plaster Cast ShearsPlaster shears with spring mechanism.
Code SizeLA4609 22cm
Stille Plaster Shear 9 Inch (23cm) serrated upper blade. Stainless steel. Reusable, fully autoclavable.
Code SizeNV1120 23cm
scissors
Code SizeNV0086 18cm
Utility ScissorManufactured from stainless steel with a plastic handle, these all purpose scissors can cut through various materials of different densities and thicknesses.
Lister Bandage Scissors 7” Inch (18cm) tungsten carbide. Tungsten carbide, 24 carat gold plated handles. Stainless steel.
Code Size NV0075 18cm
Straight Jaw Dressing ScissorStainless steel.
Code SizeNV0061 15cm
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Standard Impression Boxes Sold in packs of 25 boxes.
Code Depth
SA0451 40mm
SA0452 55mm
X-Large Impression Boxes Sold as pack of 6 boxes.
X-Large foot impression box fits up to size 15 foot.
Code Depth
SA0453 55mm
Code Size
SF5242 15kg Tub
SF5244 25kg Tub
Plaster of ParisFine Casting Plaster is a hemihydrate plaster (CaSO4.1/2 H2O) produced from naturally occurring gypsum mineral. We currently supply this product in poly tubs. This ensures safe transport and allows for a clean working environment.
plaster and alginate
Code Size
SF5241 10kg
Vermiculite Super Fine Filler for plasters and resins due to its bulking and lightening properties.
Alja-Safe® Alginate PowderSuitable for making moulds of body parts, Alja-Safe® Alginate Powder is easy to use and cures quickly. It is safe for use on human skin, reproduces fine detail and produces excellent temporary moulds.
Code Size:
RA3236 1.3Kg
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Rasps - One Wire ‘Blade’Code Description Size
LA3544 Flat 280mm
LA3548 Round 300mm
Code Description Size
LA3546 For Flat Rasp 280mm
LA3549 For Round Rasp 300mm
Replacement Blades
Flat File with RaspCode Description Size
LA3552 Flat 440mm
Code Description Size
LA3558 For Flat Rasp 440mm
Replacement Blades
Surform ShaverCode Description
LA3550 Shaver with blade
LA3551 Replacement blade
Circular Rasp
Code Description
LA3445 Circular rasp with blade
LA3555 Replacement blade
cast rectiFication tools
Plaster Mixing Bowl Flexible bowl manufactured from natural rubber.
Code Size
LA2117 0.5 Litres
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Wire BrushHeavy duty steel wire brush with stay-clean tough plastic handles and scraper attached. For removal of dirt and to prepare rough surfaces for application.
Code: Description:
LA3560 4 Rows
casting sundries
Casting PillowHelps create an accurate and reproducible model of the foot. The unique pillow shape and density allows the uncompensated foot to be suspended while maintaining neutral subtalar joint alignment as it bears load.
Code: Description
OG2019 Black
Code Description
SF5245 7 Inch
Indelible Writing PencilUsed for marking casts.
Wire BrushCode Description
LA3560 4 Rows
Lions Tongue - Screen-backCode Grit Size
LA1231 120 Grit 280 x 230mm
LA1279 180 Grit 280 x 230mm
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SG500 One Hand Cast SawProduct code: NV3418
Lightweight oscillating, one hand cast saw allowing for easy one-handed use.
Includes: 1 x Allen key, 1 x 50mm Sawblade and 1 x 65mm Sawblade.
● Speed: 12,000 - 21,000 oscillations/min ● Noise level : 85 dB ● Weight: 1.1kg ● Charging Voltage: 240V
Oscimed Cast Saw Product code: LA4631
Very popular economically priced, ergonomic, modern and compact cast cutter/saw. Innovative balancing system by belt, allowing easy one-handed use without effort and without getting tired.
Supplied with 2 blades: 50mm and 65mm.
● Speed: 12,000 to 21,000 oscillations/min ● Noise level : 65-78 dB ● Weight: 1.07kg ● Voltage: 240V
Oscimed Replacement BladesCode: Description
LA4634 Blade - 50mm
LA4635 Blade - 65mm
cast saws
Oscimed VacuumProduct code: LA4639
Dust vacuum for use with the Oscimed Cast Saw. Possesses 4 levels of filtration and filters dust down to 3 microns. Includes a support for the saw, as a well as a vacuum hose.
● Capacity: 20 litres ● Weight : 12 kg ● Voltage: 240V
SG500 One Hand Cast SawBattery Powered Product code: NV3413
Lightweight oscillating, one hand cast saw with battery and charging unit.
Includes: 1 x Battery, 1 x Charging unit, 1 x Allen key, 1 x 50mm Sawblade and 1 x 65mm Sawblade.
● Speed: 15,500 - 21,000 oscillations/min ● Noise level : 85 dB ● Weight: 1.1kg ● Charging Voltage: 240V
Casting & Forming
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SG600 Cast Saw Product code: NV3410
Oscillating cast saw. Ideal for cutting plaster and synthetic bandages.
Includes: 1 x set of wrenches, 1 x 50mm sawblade and 1 x 65mm sawblade.
● Speed: 12,000 to 21,000 oscillations/min ● Noise level : 70 dB ● Weight: 1.8kg ● Voltage: 240V
SG600 CompleteProduct code: NV3411
Includes SG600 Cast Saw & Dust Extraction
This full cast cutting solution includes:
● SG600 Cast Saw (as above) ● 240v Dust Extraction Unit ● Unit Handle ● Cast Saw Holder
Replacement blades Code Circumference
NV3430 50mm
NV3431 65mmStandardØ 50mm
Heavy DutyØ 65mm
cast saws
SG800 Cordless Cast SawProduct code: NV3416
Oscillating, battery powered cast saw.
Includes: 1 x battery, 1 x charging unit, 1 x set of wrenches, 1 x 50mm sawblade and 1 x 65mm sawblade.
● Speed: 14,500 oscillations/min ● Noise level : 70 dB ● Weight: 1.3kg ● Charging Voltage: 240V
Spares for Scheiber SawsCode Description
NV3420 Charging Unit
NV3419 Replacement Battery
Casting & Forming
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Prosthetic Cast SocksProsthetic cast socks provide a smooth surface for plaster casting while protecting the residual limb. Fine gauge tubular knit cast sock which allows for great stretch in both length and width.
Code Type Type Toe Length Per Pack
CP2846 Below Knee Round 51cm 12
CP2848 Below Knee Round 61cm 12
CP2850 Below Knee Round 76cm 12
CP2852 Below Knee Round 91cm 12
CP2854 Below Knee Pointed 51cm 12
CP2856 Below Knee Pointed 61cm 12
CP2858 Below Knee Pointed 76cm 12
CP2860 Below Knee Pointed 91cm 12
CP2862 Above Knee Round 51cm 12
CP2864 Above Knee Round 61cm 12
CP2866 Above Knee Pointed 51cm 12
CP2868 Above Knee Pointed 61cm 12
Cast PantsCast Pants allow the modesty of a patient to be protected helping to eliminate embarrassing moments. The special design and use of fine gauge cotton allows for great stretch. Both legs are seam free.
casting interFaces
Code Body Length Leg Length Body Width
CP2872 40cm 40cm 25cm - 56cm
Foot Cast Socks Foot Cast Socks make taking casts of the foot quick and clean. Designed specifically for taking casts of the foot, The Cast Socks feature a special reciprocated heel and toe that helps the sock conform to the foot.
Code Shoe Size Socks Per Pack
CP2874 8 12
CP2876 9 12
CP2878 10 12
CP2880 11 12
CP2882 12 12
CP2884 13 12
CoolMax Cranial SockThe CoolMax cranial sock was designed as a casting interface for infant cranial remoulding orthoses. It intimately conforms to the shape of the child, so that it reflects well when working with lasers.
Code Description
CP2886 Cranial Sock
CP2888 Cranial Sock with Ties