Pedorthic Manufacturing Lab

Question 1

Oven

Answer 1

Essential

Heat thermoplastics, rubbers, foams to working temperature for thermal molding.

Question 2

Thermal molding

Answer 2

Essential

One of first steps in manufacturing: create shell or base of orthotic.

Question 3

Vacuum press

Answer 3

Essential

Used in conjunction with oven; press thermoplastic and other heat moldable materials to a cast/mold of patient’s foot

Question 4

Band saw

Answer 4

Essential

Long continuous blade of metal stretched between two tensioned wheels; cut larger/thicker/heavier materials. Often used to split sole of shoe for modification.

Question 5

Grinder (general)

Answer 5

Essential

Grind plane and modify all types of material in all stages of manufacturing.

Question 6

Belt style grinder

Answer 6

Long sanding belt tensioned between two wheels for continuous joint grinding surface
Accessories permit use from rough shaping process through to buffing and finishing
MULTIPLE sanding belts and accessory wheels attached to main spindle
Self contained dust collection system

Question 7

Barrel grinder

Answer 7

Single unit, single barrel on a spindle

May or may not have self-contained dust collection system (external setup if absent)

Question 8

Wire brush

Answer 8

Grinder accessory: coarsely abrade or remove material from hard surfaces

Question 9

Scotch Brite buffing wheel

Answer 9

Grinder accessory: buff and smooth rough surfaces during finishing process

Question 10

Polishing/Finishing wheels

Answer 10

Grinder accessory: Cotton/horsehair polishing wheels
Nylon/wool/felt finishing wheels
Used in shoe modification and cleaning/finishing a shoe

Question 11

Fume hood

Answer 11

Essential (or Downdraft table)

Gluing station: area in which solvent-based glues used safely; pulls fumes up and out through external exhaust system

Question 12

Downdraft table

Answer 12

Essential (or fume hood)

Gluing station: area in which solvent-based glues used safely; uses downward suction to pull fumes down and out through external exhaust system

Question 13

Advantage of downdraft table vs fume hood

Answer 13

Vapours from solvent based glues often heavier than air; more effectively pulled down (downdraft) than up (fume hood)

Question 14

Dremel

Answer 14

Essential

Rotary tool: grinding, buffing, sanding, shaping in finer detail; excavations, bevelling holes, other small changes to orthosis

Question 15

Basic hand tools: scissors, utility blades, shears

Answer 15

Essential

Cut away excess material, split or cut shoes, fitting process of orthotic into footwear

Question 16

Basic hand tools: Calipers

Answer 16

Essential

Precisely measure, compare, or replicate thickness of materials or additions

Question 17

Basic hand tools: Heat gun

Answer 17

Essential

Used in both manufacturing and deconstruction of orthoses/footwear; commonly in finishing stage for materials where oven is too much heat; adhere cushioning laters, top covers, additions; splitting shoe sole, altering orthotic for adjustment

Question 18

Table saw

Answer 18

cutting larger stock of material into smaller pieces; large sheets from distributor cannot be safely cut with band saw alone

Question 19

Material blanks

Answer 19

Smaller or more manageable pieces of an originally large sheet of material from distributor

Question 20

Thickness planer

Answer 20

Abrading large surfaces/thermoplastics, thinning larger stock material; also found in woodworking

Question 21

CAD/CAM mill

Answer 21

produce milled orthoses in clinics using computer-aided design/manufacturing system

Question 22

Milled vs vacuum-formed

Answer 22

Milled = no physical mold; virtual mold after scan, correct, store image of cast; can be more rigid or thinner
Vacuum-formed = physical mold; widest variety of orthotic modification

Question 23

Shoe press

Answer 23

Non-essential: firmly press sole of shoe to upper; used when applying a lift or another outsole modification to a shoe; manual or hydraulic

Question 24

Belt sander

Answer 24

Plane an orthoses evenly along large surface; obtain flat, even surface along base of orthosis

Question 25

Shoe stretcher

Answer 25

In clinic and in lab; increase width, depth, seam flexibility; spot stretch upper of shoe for deformity

Question 26

Thermoplastics

Answer 26

Core material category High density polyethylene (HPDE), polypropylene Fabrication of orthotic shell

Question 27

Urethanes

Answer 27

And foams: Core material category Plastazote, p-cell, poron, aliplast, neolon Top covers or cushioning layers

Question 28

Ethylene vinyl acetate (EVA)

Answer 28

Wide variety of purposes | Orthotic shells, posting, heel/shoe lifts, additions, modifications, metatarsal bars

Question 29

Cork

Answer 29

Core material category Natural/synthetic for posting Accommodative orthotic shell, other

Question 30

Carbon fibre composites

Answer 30

Core material category | Firmest orthotic shells, foot/toe plates

Question 31

Specialty materials

Answer 31

Core material category Silicone, fabrics, leather, etc Top cover, interface between orthotic and foot Silicone: cushioning, accommodative purposes

Question 32

Pre-fabricated components

Answer 32

Core material category | Metatarsal pads, scaphoid pads, neuroma pads, heel lifts/wedges

Question 33

Durometer

Answer 33

Key material property | Surface resistivity or material hardness

Question 34

Durometer 15 or 20

Answer 34

Low = cushioning

Question 35

Durometer 60 or 70

Answer 35

High = footwear modifications, shoe lifts

Question 36

Thickness

Answer 36

Key material property Most often measured in mm or inches Sometimes described in irons

Question 37

48 iron

Answer 37

25.4mm = 1 inch

Question 38

Heating/working time

Answer 38

Key material property | Manufacturer’s guideline on how long to heat a material in order for it to be workable

Question 39

Colour, size, quantity

Answer 39

material properties

Question 40

WHMIS

Answer 40

Workplace Hazardous Materials Information System Canada’s national hazard communication standard; ensure workers receive health and safety information about hazardous products they may be exposed to in their workplace

Question 41

Employee’s WHIMIS duty

Answer 41

responsible for taking training and necessary measures to protect themselves and co-workers, identify and control hazardous materials

Question 42

Employer’s WHIMIS duty

Answer 42

Ensure hazardous materials are properly labeled, to have safety data sheets available, to offer education/training about products in the workplace