Abstract: Systems and methods for forming a custom fitted shoe insole. The method includes placing a shoe insole template plate proximate a heating element that heats the shoe insole template plate to a temperature sufficient to make it deformable. The method further includes placing the sufficiently heated shoe insole template plate onto a foam structure, placing a foot of a user on the heated shoe insole template plate, and applying foot pressure to the heated shoe insole template plate, causing it to deform to match a topology of the sole of the user's foot. The shoe insole template plate is then removed from the foam structure, cooled and hardened, and inserted into a shoe as the custom fitted shoe insole.

Abstract: An impression device has a base having a recess and a conduit for fluidly coupling the recess to a vacuum source configured to temporarily apply a vacuum pressure to the recess. The device has a first plurality of particles positioned in the recess, the first plurality of particles sealed from an external environment and consisting essentially of a plurality of circular glass beads. The device has a flexible membrane coupled to the base adjacent to the first plurality of particles and holding the first plurality of particles in the base. The first plurality of particles has a first coefficient of friction between each other selected to allow the particles to move relative to each other in the absence of the vacuum pressure and to prevent the particles from moving relative to each other in the presence of the vacuum pressure.

Abstract: A closed cushion system including a device for selectively opening a connection between adjacent fixed, pre-filled chambers is set forth. The connection selectively facilitates flow of a fill material between the pre-filled chambers in order to selectively alter the firmness of the pre-filled chambers.

Abstract: A machine may be configured to re-create an internal shape of a clothing item using a pneumatically-powered fitting device. For example, the machine, based on a clothing item identifier, identifies a description of an internal shape of a clothing item. The machine transmits an instruction referencing the description to a filling station associated with the fitting device. The machine, based on the transmitting of the instruction, causes the fitting device to adjust according to the description.

Abstract: The present disclosure provides a custom or pre-fabricated ankle foot orthosis providing tri-planar control of the ankle foot structure. The ankle foot orthosis comprises a brace body composed of reinforcement strips and a closure mechanism.

Abstract: A method of making an orthoses, comprising the steps of preparing a plaster mold, upon which the layers of the orthosis will be placed and formed; and placing layers of material on the mold, then forming and removing the layers. An orthosis, comprising a footplate that is capable of receiving a human foot thereabove, a heel portion at the rear side of the footplate; a strut extending upwardly from the heel portion; a calf portion extending forwardly from the strut, the calf portion including a tibial shell; the tibial shell extends around the front of the user's tibia; a rear portion extends around the back of the user's calf a rear portion disposed rearwardly with respect to the calf portion; and sides such that the calf portion is completely circumferential without seams. Two foam layers line the orthoses for comfort and ease of use.

Abstract: A system and method for making a golf ball having a patterned surface is disclosed. The pattern may be made by a method including machining a pattern of feed marks on the surface of a golf ball mold and using the golf ball mold to mold a golf ball cover layer. The pattern may be configured to create capillary action to substantially counteract gravity and/or other forces acting on a substantially liquid coating material applied to the cover layer of the golf ball.

Abstract: An impression system is provided for capturing an anatomical impression of an animal. The impression system comprises a foam that substantially retains an impression after application of pressure and subsequent removal of pressure and a case having a recessed area for receiving the foam and a case for retaining the foam therein. The system further comprises a cover having a viewing pane attachable to the case for providing viewing of the foam when closed.

Abstract: A novel bike shoe (and related methods of use and fabrication) and bike shoe/pedal system that allows the rider to either slide their foot in and out of the shoe while it remains attached to the pedal or mount/dismount from the pedal while wearing the shoe.

Abstract: Disclosed is a method for producing a three-dimensional composite structure and a method for producing the mold for the three-dimensional composite structure. The mold is formed of at least one rigid die member and a second thermoplastic die member. The second thermoplastic die member is formed by coupling a rubber flexible pattern to a surface of the first die member. Vacuum or pressure is applied to a heated thermoplastic sheet to cause the heated thermoplastic sheet to deform about the flexible pattern, thereby forming the second die. Strips of reinforced polymer thermoset pre-preg material are then positioned within the cavities formed by the flexible pattern and are allowed to cure. Optionally, heat, pressure, and vacuum may be applied to the mold construction to facilitate the curing of the thermoset materials.

Abstract: An exemplary method for making a mold used for molding lenses includes the following. First, a base is provided. The base has parallel lines marked on a surface thereof. Second, a dispenser is provided. The dispenser dispenses lumps of molding material on selected positions on the surface of the base guided by the lines. Third, a roller is provided. The roller has a peripheral side surface. The peripheral side surface has spaced molding surfaces defined thereat, each molding surface corresponding to a surface of a lens to be formed. The roller is applied above the base, with the molding surfaces press-molding the lumps of molding material, thereby forming molding portions on the base. Thus, a mold including the base and the molding portions formed on the base is obtained.

Abstract: A tire mold having a substantially elliptical base surface and a method for making a tire mold are provided. In one embodiment, a user selects a major axis length for the tire mold, then selects a ratio of the major axis length to a minor axis length. The tire mold is then formed with a substantially elliptical base surface defined by the first major axis and the selected ratio.

Abstract: A method and apparatus for the making of an impression of a person's foot in foam to be used in the manufacture of orthotics comprising in combination a box of foam that will be deformed by the person's foot during the making of a foot impression, placed in foam box receptacle that is supported on a base and which can adjustably swivel or rotate so that the person's knee, ankle and foot will be put in a neutral position and when in use the person is placed in a seated position and a box of foam is placed in the receptacle and a strap assembly is used to exert a downward force on the person's lower leg, the strap being secured to a lever arm used to exert a downward pressure and engage with a block arm which correspondingly exerts a downward force on a block situated above the box of foam and which pushes the foot down into the foam and wherein the block is slideable transversely to the box of foam to align with the arch of the person's foot and to insure that the block exerts its downward pressure evenly and

Abstract: A method for making a component of boot body for a skating shoe includes a cutting step, a mold-making step, a coating step and a shaping step. The cutting step cuts a flexible sheet to form a base sheet with at least one predetermined coating area. The mold-making step forms a coating mold with at least one coating slot. The coating step applies epoxy resin to the base sheet to form a layer of epoxy resin coating and applies the epoxy resin to the at least one predetermined coating area through the at least one coating slot to integrally form at least one reinforcement on the base sheet. The shaping step heats and pressurizes the base sheet to form a component of a boot body. The at least one reinforcement provides an improved hardness and impact strength to the boot body and keeps a user's foot from injury.

Abstract: An orthopedic casting slipper kit for custom molding of a foot impression including a low-cut impression slipper shaped to extend upwardly on a patient's foot from a plantar surface of the foot to an open end. The impression slipper is made from a fabric that is sufficiently resilient so as to enable the impression slipper to substantially conform to the patient's foot. A support element is coupled to the impression slipper and extends around at least a portion of the patient's foot for holding the impression slipper snug against the patient's foot. A quantity of curable resin is provided for impregnation into the fabric of the impression slipper and is sufficient to harden the impression slipper into a cast foot impression.

Abstract: Methods and apparatuses for manufacturing components used in the manufacture of wearable articles are presented. Some of the methods of manufacturing a mold and the apparatuses themselves include, among other features, forming a plate having a mold insert. The mold insert is removably connected to the plate and is formed using a rapid prototyping technique. In addition, methods for manufacturing wearable articles are presented. The methods generally including forming a mold, including a mold insert formed using a rapid prototyping technique. In addition, the methods include performing the steps of a molding operation on the mold. The molding operation may include any of several known molding operations.

Abstract: The present invention to be personalized is fitted with a sealed chamber. The chamber is defined by an object and a thin, flexible member. When it is desired to personalize the object, the sealed chamber is filled with uncured paste having predetermined characteristics. The object to be personalized then is brought into contact with a human; thereafter, the paste cures in place to complete the personalizing process.

Abstract: A method of sizing, resizing or reshaping the interior of a prosthetic device includes placing a lightweight moldable or shape assuming, pliable material that adheres and hardens on the interior sides of a socket of a prosthetic device. An end of a residual limb is placed into the socket causing the moldable material to conform to the shape of the residual limb. The limb is maintained in position for a few minutes in the socket until the moldable material has sufficiently hardened. After hardening, the molded material is dressed down, sanded or feathered to remove any burrs or sharp edges. Low spots or holes may be filled in with more moldable material and the fitting process repeated.

Abstract: The present invention discloses an apparatus which enables in-situ casts of the feet of a patient to be made whilst the feet support the patient's weight. In particular, two heel supports (28, 29) and two stirrups (38, 39) receive the heels and forefeet of the patient. Each is capable of independent movement being both rotation about the heel-toe axis and movement substantially transverse to that axis. A method of forming a cast of the patient's feet is also disclosed.

Abstract: A method of forming prosthetic sockets is provided that first creates a negative mold of the patient's residual limb while it is disposed in a positive flexion position. The mold is then removed and shaped to permit the desired range of flexion when the mold is repositioned on the residual limb. A second cast is made of the residual limb that incorporates the mold. A positive model of the residual limb is then formed, from which test or definitive sockets may be formed. The present method further lends itself to the formation of sockets using a cast-in-place methodology while the limb is disposed in a positive flexion position.

Abstract: A prosthetic socket is made by wrapping water-soaked plaster bandages around a residual limb or around a prosthetic liner within which is disposed a residual limb, and positioning a vacuum wick in overlying relation to the plaster bandages. The residual limb, prosthetic liner, plaster bandages, and vacuum wick means are then inserted into a vacuum bladder. The vacuum bladder is sealed and a predetermined vacuum is applied internally to the bladder until the plaster hardens into a negative cast. The residual limb is manipulated through the vacuum bladder to modify the geometry of the plaster before the plaster hardens. The negative cast is removed from the residual limb and a positive cast is produced by pouring plaster into the negative cast. A thermoplastic sheet is thermoformed over the positive cast or a carbon-epoxy matrix is laminated over the positive cast. This eliminates reduction and modification of a hard positive cast.

Abstract: An orthopedic casting slipper kit (21) including a resilient fabric impression slipper (23) formed to extend on a patient's foot (27) from a plantar aspect or surface (29) to about one-third of the way from the base of the toes to the dorsum of the foot. A longitudinally resiliently extensible band (37) is provided on the slipper (23) proximate the open end (33), and an arch strap (39) dimensioned to span transversely over the dorsum (30) of the foot (27) is used to pull the impression slipper (23) up into contact with the arch (35) of the foot to prevent bridging of the arch. A method of using the arch strap (39) to aid in conformance also is disclosed.

Abstract: A method of manufacture of footwear and the footwear comprising the steps of providing a last with an upper thereon, providing a mold insert on the bottom of the last, providing a mold having a mold cavity for a tread sole, disposing the last and upper against the mold with the mold insert disposed within the mold cavity, forming a sole in the mold cavity having a depression therein in the shape of the mold insert, providing an insole with a first portion in the shape of the depression and a second portion substantially in the shape of the sole and securing the first portion of the insole in the depression. The tread sole and insole are formed of materials preferably having different physical properties. The tread sole can include one of tongues and grooves and the insole would then have the other of tongues and grooves, said tongues and grooves mating with each other.

Abstract: A system, method and device for the symptomatic relief for soft corns by injecting a medical grade molding substance between the toes between which a corn is located, forming a molded-in-place, custom-shaped high definition mold, unique to the individual's physical conformation and which reduces friction and eliminates pressure points on the corn.

Abstract: A custom-fitting prosthetics liner is made without mixing silicone and without making a mold. A thermoformable liner is made by preparing a negative cast from a patient's residual limb, preparing a positive cast from the negative cast, and placing a thermoformable tubular liner over the positive cast. The positive cast and liner are heated in an oven for a predetermined time and temperature. Having acquired a new geometry, the cast and liner are removed from the oven and allowed to cool to room temperature. The liner is then removed from the cast. Alternatively the liner is heated, placed over the positive cast, cooled and removed. The interior surface of the liner conforms to the shape of the cast. The liner is elastic so that it returns to its new geometry when stretched and released. It therefore holds on to a residual limb even when the residual limb shrinks.

Abstract: A custom shoe sole manufacturing system for efficiently creating a custom shoe sole. The custom shoe sole manufacturing system includes the steps of forming a negative impression of a foot within a foam member, vacuum forming a seal about the negative impression, positioning a casting frame about the negative impression, filling the casting frame with a casting material, removing the casting frame after casting material is hardened, positioning a liner upon the positive impression, securing a cover member about the casting frame, inputting a polymer into the cover member and casting frame, and removing custom shoe sole from casting frame after polymer has hardened.

Abstract: A method of manufacture of footwear and the footwear comprising the steps of providing a last with an upper thereon, providing a mold insert on the bottom of the last, providing a mold having a mold cavity for a tread sole, disposing the last and upper against the mold with the mold insert disposed within the mold cavity, forming a sole in the mold cavity having a depression therein in the shape of the mold insert, providing an insole with a first portion in the shape of the depression and a second portion substantially in the shape of the sole and securing the first portion of the insole in the depression. The tread sole and insole are formed of materials preferably having different physical properties. The tread sole can include one of tongues and grooves and the insole would then have the other of tongues and grooves, said tongues and grooves mating with each other.

Abstract: A composite material blank for an orthotic insert. The device is formed of layers of fiberglass and graphite fiber material. A first graphite fiber layer provides the overall structure with increased strength, while secondary graphite fiber reinforcement strips are arranged below the first and fifth rays of the foot to provide additional rigidity and control in these areas. The edges of the graphite fiber layers are recessed inwardly from the edges of the fiberglass layers so as to provide a graphite-free border which prevents cracks from propagating into the graphite fiber layers. The layers are bonded together by heat curing over molds.

Abstract: A footwear manufacturing system for providing an efficient and economical system for manufacturing affordable custom footwear. The footwear manufacturing system includes measuring a foot, creating a foot profile, transmitting the foot profile to a manufacturing station, utilizing the foot profile to generate a positive impression within a mold, and injecting the mold with a liquid forming about the positive impression and hardening. Various foot measuring techniques may be utilized to create the foot profile. The manufacturing station preferably utilizes a mold utilizing a plurality of adjustable pins that manipulate a membrane within the mold to create the positive impression.

Abstract: The device and method of the invention utilizes a vacuum pump, a casting device, first and second CIR Connectors, a connector cuff, a casting balloon, a heating chamber or oven, a supracondylar wedge, and a CIR alignment/vacuum forming jig to create a prosthetic device under field conditions.

Abstract: An orthotic device developed and customized to control the desired movement of the patient's defective lower limb. The device incorporates a footplate made of a rubber-like elastomeric material and a proximal segment that encompasses the foot at the metatarsophalangeal joints and the shin portion of the leg. This proximal segment is made of a rubber-like elastomeric material laminated into multiple layers of fabric throughout the proximal segment. Additional strips of fabric are positioned within the proximal segment of the device to limit or promote certain motions within the foot and ankle. This device incorporates a continuous closure from the foot to the proximal segment, creating total contact and hydrostatic containment of the foot and lower leg.

Abstract: A kit and method for creating an article display includes a frame having two openings. The completed display includes a clay tablet having an impression formed therein located within one of the frame openings and a picture located in the other frame opening. The invention is suitable for making impressions of baby's hands or feet and displaying a picture of the baby along with the tablet carrying the impressions.

Abstract: Methods for reproducing a 3D object surface are provided. A preferred method according to this invention includes (1) identifying a real object surface, (2) acquiring at least a 3D data set with a 3D surface imaging device, (3) acquiring at least a 2D data set using a 2D surface imaging device with a surface resolution of at least about 0.1 mm2, (4) synthesizing a 3D composite data set by orienting a first virtual image of the first data set and a second virtual image of the second data set to form a composite virtual image that corresponds to the composite data set, and (5) making a reproduction of the object surface with the composite data set. Orientation of the virtual images is relative to each other and without substantial loss of surface resolution.

Abstract: An impression of a portion of a human body is made by forming a preform of tandard profile of polymeric material with shape memory that is substantially rigid at ambient temperature and flexible and elastic at a higher working temperature, bringing the preform to that working temperature, and placing the preform on that body portion. After cooling of the preform to below the working temperature, the preform is removed from the body portion and a positive model is cast from the preform. The preform is then returned to the working temperature without physical constraint, whereupon the preform resumes its standard profile and so can be re-used a number of times. The polymeric composition comprises at least one elastomer and one polycaprolactone diluted in a composition of solvents that dissolve the polymers. The elastomer is polyurethane. The composition of solvents comprises dimethyl-formamide to dissolve the polyurethane, toluene to dissolve the polycaprolactone, and methylethylketone as a buffer.

Abstract: The invention relates to a material of a three-dimensional framework of supporting, trabecular structures encompassing cavities which are connected with one another and which can be predeterminedly adjusted. The material is obtainable by forming the framework around the shaped bodies serving as space retainers for the cavities and subsequently removing the shaped bodies. The material according to the invention can be used for example as a implant or as a filter.

Abstract: An apparatus for neutralizing the leg of a person during the molding of an orthotic is disclosed. The apparatus includes a base, a movable standard supporting a knee caliper and ankle caliper. The knee caliper and ankle caliper have arms movable by a crank to center the knee and ankle on a plane extending through the orthotic. The calipers have height adjustments.

Abstract: The invention provides a method for preforming soles which includes compressing a foot so as to push soft fat tissue masses of the foot on its underside and inner and outer lateral arches inward toward a top of the leg; making an accurate molding of the foot thus compressed by using material for making the molding which is capable of flowing into cavities which result from the compression of the foot and which is capable of filling the cavities; removing the foot from the molding; and placing a sole blank on a bottom of the molding, the blank preferably having been treated so as to be capable of being shaped by pressure from a foot on it; and pressing the foot, which is still compressed, onto the blank so as to shape it between an inner face of the foot and the bottom of the molding.

Abstract: A composite material blank for an orthotic insert. The device is formed of layers of fiberglass and graphite fiber material. A first graphite fiber layer provides the overall structure with increased strength, while secondary graphite fiber reinforcement strips are arranged below the first and fifth rays of the foot to provide additional rigidity and control in these areas. The edges of the graphite fiber layers are recessed inwardly from the edges of the fiberglass layers so as to provide a graphite-free border which prevents cracks from propagating into the graphite fiber layers. The layers are bonded together by heat curing.

Abstract: A system and method for making an impression of a foot, an ankle, and a lower leg to be used in the fabrication of custom-made shoes. The system has a molding component made of a compressible foam or a combination of compressible foams made into prefabricated pieces, and a protective component made of plastic, cardboard, or other disposable material enclosing the molding component. The protective component may be securely affixed to the molding component and is designed to be used for mailing or storing the foot-ankle-lower leg impression.

Abstract: A mold apparatus for use in manufacturing bespoke complementarily contoured cushion members such, for example, as cushion insole members for footware for subjects with foot deformities employs a large multiplicity of rods 15 supported at their ends by first and second flexible membranes 17, 19 formed from a medium viscosity silicone rubber. Under finger pressure applied at a surface say 19a of the membrane 19, the membrane 19 is locally deformed, the rods 15 sliding with respect to one another so as to produce complementary deformation at surface 17a of the other membrane 17. Clamp means 18 is operable by increasing friction between the rods 15 to prevent the rods from subsequent relative sliding movement.Using the apparatus a bespoke cushioned insole for footwear may be produced to complementarily conform with the contoured surface 19a created by pressing the latter surface into intimate contact with a subject foot whilst the foot is in contact with the surface 17a.

Abstract: An orthosis to support the sole of a foot of a person comprising a support surface having a shape conforming substantially to the shape of the sole of the foot and the support surface comprises a first opening underlying a first portion of the sole of the foot.

Abstract: The body part mold system includes a method of making accurate replicas of body parts, with the steps of the method comprising using an elongate prefabricated hollow transparent support form having an opening at one end and a slit on one side, inserting the body part through the opening into the form, sealing the slit so as to be leak-proof, pouring into the support form a liquid molding material containing alginate that rapidly sets to form a gelatinous matrix containing a negative impression of the body part, releasing the body part from the mold to leave a negative impression of the body part, casting a replica of the body part in the mold, and removing the replica from the mold. The method yields accurate replicas of body parts for medical, artistic, and other uses. The support forms may be either rigid or somewhat flexible, and are reusable. The transparency of the support forms permit precise positioning of the model or patient and monitoring of the filling of the form with molding material.

Abstract: An insert forming apparatus is provided for making an insert to conformingly fit a shoe and a person's foot within the shoe. The apparatus includes an upper and lower shell half which, when fastened together, form a foot receiving cavity that conformingly fits the individual contours of the last from which the person's shoes are made. The apparatus also includes an injection tube for injecting insert forming material into the foot receiving cavity under and about the person's foot.

Abstract: A method of forming a bodyweight supporting, pressure-equalized impression of the foot, generated by an apparatus that creates a dynamic state to the foot, simulating the gait cycle of human ambulation. The foot and impressionable material are placed on granular particles within a container. The container is mounted to a base with a turntable between them. A planar, elongate insert is partially inserted within the granular particles. The base has a guide pin that fits through an opening in the container into a track in the insert. The insert is removable by pulling and when the insert is removed the granular particles and accompanying foot shift to fill the volume previously occupied by the insert. The shifting movement begins at the heel of the foot and continues progressively past the toes. Also, as the insert is removed the container pivots on the turntable in adduction. The inserts track slides along the guide pin controlling the amount and timing of the twist.

Abstract: An insert forming apparatus and method is provided for making an insert to conformingly fit a shoe and a person's foot within the shoe. The method for practicing the invention includes using standard molding techniques to form a mold of the bottom of the last and using the mold to vacuum form a lower shell half that conforms to the bottom of the last. With the lower shell half covering the mold and having vacuum communicating holes drilled therein, the last is placed in the lower shell half and the upper shell half is drawn down over the last and lower shell half by vacuum forming. When the upper and lower shell halves have been formed, a hole is drilled in the lower shell half for injecting curable material. A sheet of fabric or leather is placed over the lover shell half, a person's foot is placed on the fabric or leather in the lower shell half, and the upper shell half is placed over the person's foot and fastened to the lower shell half.

Abstract: A molding material for constructing h of living models comprises a composition of alginate powder, water, and chopped polystyrene. This composition is useable in a method of making one-piece head molds or one-piece hand molds of living models by applying the composition to the head of a model, wrapping the composition-covered head in plaster bandages until the composition has cured, removing the bandages, cutting the cured mold so that the model can be freed from the mold, placing the cut edges of the mold in register, and replacing the plaster bandages.

Abstract: A self-lubricating ocular prosthesis includes a solid rigid prosthetic eye body with a chamber in the body opening through an access passage through the posterior surface of the body closed with a releasable cap having an outside face conforming to the posterior surface of the body which abuts the orbital cavity. The cap is of a semi-rigid or flexible polymeric resin to retain a fluid in the chamber which is dispensed through bore openings from the chamber through the surface of the eye body. Liquid may be inserted directly into the cavity through the bore opening while the prosthesis is in place. The prosthesis may also include a dispensing ball or depressible button to dispense fluid from the prosthesis.

Abstract: A method and apparatus for producing an insole for a foot including defining a flexible insole housing in which is disposed a deformable material impregnated with an uncured resin, activating the resin for initiating curing thereof, locating the foot on the insole housing and allowing the resin to harden and thus, to preserve the configuration defined by the bottom of the foot.

Abstract: A method and apparatus for producing an insole for a foot including defining a flexible insole housing in which is disposed a deformable material impregnated with an uncured resin, activating the resin for initiating curing thereof, locating the foot on the insole housing and allowing the resin to harden and thus, to preserve the configuration defined by the bottom of the foot.

Abstract: A method and apparatus are provided for relatively convenient and efficient production of custom molded inserts for shoes. The apparatus utilizes a molding pillow arrangement, upon which a user stands during use. The molding pillow arrangement has a composite construction including a first resilient layer, a middle resilient layer and a bottom support layer. The bottom support layer preferably includes a generic arch curve therein. The upper resilient layer is formed from a relatively soft foam, and thus molds around a user's feet. The middle layer is resilient, but relatively hard by comparison to the upper layer. The middle layer provides for a relatively firm cushion underneath the user's foot, facilitating contouring of a molded insert to the bottom of the user's foot. Preferably, at least the upper cushion portion of the molding pillow arrangement comprises left and right cushions, independently moldable with respect to a user's left and right feet.