A Sample Fabrication Process of an AFO 

 Step 1:
Creating a negative plaster mould of patient's lower leg and foot

After consultation and evaluation of the patient's requirements, a negative plaster impression is taken of the necessary body part.

 Step 2:
Cutting and removing plaster mold from patient

After the plaster cast has hardened, it is removed from the patient and sealed. 

Step 3:
Pouring liquid plaster into the negative plaster mold

The negative plaster cast is placed in a box of sand and filled with liquid plaster and then left to harden. 

Step 4:
Modifing the positive plaster cast

The plaster cast is peeled from the positive mold and discarded. The positive mold is then modified to apply the appropriate corrections to the cast. 

Step 5:
Moulding the plastic

The positive plaster cast surface is smoothed. Plastic is then vacuum formed to the plaster cast. 

Step 6:
Cutting and removing the plastic from positive cast

After the plastic has cooled, it is cut out to the rough shape to be ready for finishing. 

Step 7:
Finishing the plastic shape

The orthosis is now finished to the final shape and the edges finished. All pads are glued inside and the brace is now ready for fitting. 

Step 8:
Fitting the patient

The finished orthosis is now ready to be fit to the patient. During the fitting, the orthosis is checked for fit and comfort. Then the patient is walked to ensure the original purpose is achieved. A follow-up appointment is arranged to ensure fit and function is ideal and that no adjustments need to be made