Abstract: A number of different methods for applying a layer of cushioning material to a surface of an article are provided, whereby the thickness of the cushion layer can be controlled to a high degree of precision and the profile of the cushion layer can also be controlled and varied depending upon the application.

Abstract: An improved cushioned liner (i.e., prosthetic liner) for covering a residual limb of an amputee is provided. According to one embodiment, the cushioned liner includes a sock-shaped fabric body member formed of at least two fabric pieces. One of the fabric pieces is a distal end piece that is attached to at least one other fabric piece along a circumferential edge of the distal end piece. The distal end piece is free of a transverse seam that extends across the distal end piece. The cushioned liner also includes a cushion layer disposed on at least one side of the sock-shaped fabric member. In another embodiment, a liner body having the above construction is provided and is adapted to receive cushioning material to form the cushioned liner.