Abstract: An orthosis may be made by providing a laminate material having a flexible foam material and a substantially rigid plastic sheet material sandwiched between a pair of soft flexible sheet materials. A body support is formed by heating the laminate material under conditions of pressure to soften the laminate to a pliable state, cutting the laminate to a desired shape to yield a pattern corresponding to a desired shape of the body support, providing a form corresponding to a desired configuration of the body support and positioning the pattern on the form in a pliable state, applying a negative pressure to conform the pattern.

Abstract: A cervical collar having upper and lower posterior laminate bodies each including a low density polyethylene material, a foam material, and a fabric material; and upper and lower anterior laminate bodies each including a low density polyethylene material and a fabric material.