Abstract: The present invention provides improved hardenable orthopaedic supports and methods of making the same. One embodiment provides a support which includes a blank made of a permeable, flexible material and including a structural region impregnated with a hardenable material and a peripheral region which will remain flexible after the hardenable material is hardened. Another embodiment provides a method of manufacturing an orthopaedic support in which a permeable, flexible material is positioned adjacent a recess of a molding element; the flexible material is contacted with a hardenable material; and the hardenable material is placed under pressure in the molding element to impregnate the section of the flexible material with the hardenable material.

Abstract: A technique for forming orthopaedic splints or supports includes the steps of impregnating the edges of casting material with non-rigid bonding material and subsequently impregnating the casting material with water hardenable material such as urethane. The edge treatment keeps the edges in a relatively cushioning or non-rigid state to avoid irritation of the skin of the patient. The blanks may be formed using a mold having a groove defining the outline of the casting blank, and a ridge for implementing the impregnation of a bead of bonding material into the casting fabric. The casting blank material may be formed of spacer or double knit type material, or may be formed of several layers of fabric including high strength filaments, and may have padding material as one layer.

Abstract: A technique for forming orthopaedic splints or supports includes the steps of impregnating the edges of casting material with non-rigid bonding material and subsequently impregnating the casting material with water hardenable material such as urethane. The edge treatment keeps the edges in a relatively cushioning or non-rigid state to avoid irritation of the skin of the patient. The blanks may be formed using a mold having a groove defining the outline of the casting blank, and a ridge for implementing the impregnation of a bead of bonding material into the casting fabric. The casting blank material may be formed of spacer or double knit type material, or may be formed of several layers of fabric including high strength filaments, and may have padding material as one layer.