Abstract: An improved thermoplastic material for orthoses and prostheses. This material comprises at least one resin layer of polymeric resin, optionally reinforced with multiple layers or internal fibers, designed to be compatible with vacuum thermoforming, with thickness between 3/64 inches and ¾ inches. The material additionally comprises at least one and optionally two extremely thin cap layers with thickness between 2/1000 and 12/1000 inches, at least one of which is intended for improved compatibility with human skin, and the other of which can be configured for various cosmetic or UV protection purposes. Methods of producing this material, and various orthotic and prosthetic devices using this material, are also taught.

Abstract: Material and method for reducing creep in orthotics and prosthetics. Thermoplastic resin plies and fiber veil plies with a substantially porous structure composed of discontinuous fibers held together by small amounts of polymeric binder between the fiber contact points are consolidated under heat and pressure. This causes the resin to flow into the porous voids and the binder to dissociate from the contact points, producing a composite material with an embedded fiber veil remnant that retains the three dimensional structure of the original fiber veil. The various fibers can move freely with respect to one another at melt temperature, while the orientation of the fibers in the fiber veil remnant resists bending in all directions at lower temperatures. This composite material can then be vacuum thermoformed into at least one complex component of an orthotic device or prosthetic device, such as a complex component with a double horizon bend.