Abstract
This study investigates if fabrication techniques employed at different orthotic centres affect the characteristics of the manufactured plastic orthoses.
Plaster models were formed from the same master mould. The thickness and bending stiffness of the supplied polypropylene sheets were measured prior to fabrication.
An orthotic technician at each of the 3 orthotic centres manufactured 4 homopolymer and 4 copolymer polypropylene ankle‐foot orthoses (AFOs), following each centre's fabrication practice. Another technician at one of the orthotic centres manufactured an additional 4 homopolymer and 4 copolymer AFOs. The thickness, the dorsiflexion stiffness and plantar‐flexion stiffness of the 32 fabricated AFOs were monitored and compared.
Analysis of the results suggests:
Copolymer polypropylene sheets are supplied marginally thicker than homopolymer polypropylene sheets
The difference between the thickness of the 16 copolymer and 16 homopolymer AFOs was not significant. The thickness of the AFOs manufactured in copolymer was less consistent than homopolymer.
Dorsiflexion stiffness of the copolymer AFOs was less consistent than homopolymer AFOs. Although the bending stiffness of the copolymer and homopolymer sheets differed significantly, there was no significant difference between the dorsiflexion stiffness of the copolymer and homopolymer AFOs.
Plantarflexion stiffness was consistent for both the copolymer and the homopolymer AFOs and there was no significant difference between the plantarflexion stiffness of the copolymer and homopolymer AFOs.
The thickness and flexural stiffness of the AFOs manufactured by 2 technicians at the same centre did not differ.
These results are useful benchmarks for the flexural stiffness of AFOs.