Fab Lab Express LLCOrthotic Fabrication
Casting Instructions
Your brace will only be as good as its casting and the measurements and information you supply to us. We invite you to take a look through this slideshow to become better informed as to best practices in casting.
Prepare the extremity for casting by determining the patient’s most functional and correct position depending on your patient’s condition. Placing the foot on the floor gives a great impression of what the foot and ankle looks like prior to fully weight bearing and allows the technical staff to see how much correction could be tolerated during fabrication.
Using an indelible pencil, mark all bony prominent areas and desired total height of the orthosis to be fabricated.
Begin casting with the intent of having the patient’s extremity as close to neutral as possible when completed and to ensure the cast is durable enough to endure shipping and prep for fabrication.
Make alignment marks on the cast for the purpose of realignment prior to fabrication. Heel height to accommodate foot wear needs to be indicated on the work order, as well as desired ankle position and measurements pertaining to the device.
Carefully cut and remove cast while trying not to deform the negative mold.
Be careful not to deform the cast while it’s drying.
Quality of cast can influence fit and function. The better the cast/ measurements, the better the outcome.
