Memory Foam Density:
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Ryan's Footand Body W eight 0 20 40 60 80 0 10 20 30 40 50 60 70 Depression Tim e (seconds) R e tra (s e c o Pink G reen Y ellow Memory Foam Density: Ryan's Footand Body W eight 0 20 40 60 80 0 10 20 30 40 50 60 70 Depression Tim e (seconds) R e tra c t (s e c o n Pink G reen Y ellow Ryan's Footand Body W eight 0 20 40 60 80 0 10 20 30 40 50 60 70 Depression Tim e (seconds) R e tra c ti (s e c o n Pink G reen Y ellow > > Prototype Testing: B. Memory Foam with Ziploc Bag • Held the shape of a square wooden block after air was removed • Rounded edges were not desired by Sole Supports, Inc. C. Play-Doh in Rubbermaid Container • Captured and held the foot shape and arch height • Very dense, required lots of applied force to cast the foot • Play-Doh stuck to patient’s foot after casting D. Moist Sand in Sole Supports, Inc. Casting Box • Captured and held the foot shape and arch height • Depth of cast limited due to sand compaction • Scan of sand cast met Sole Supports, Inc. specifications A. Memory Foam with Latex Exterior and Check Valve • Memory foam absorbed liquid latex instead of creating a vacuum tight exterior layer Development of a Reusable Casting Apparatus for Custom Made Foot Orthotics Keegan Compton, Ryan Cook, Michelle Sauer Biomedical Engineering, Vanderbilt University, Nashville, TN 37235 Sole Supports, Inc., Lyles, TN 37098 RESULTS Special thanks to Dr. Paul King, Mr. Matt Moore, Dr. Hak-Joon Sung, and Mr. Brad Compton for their help with this project. We also appreciate the support of the Vanderbilt Biomedical Engineering Department and Sole Supports, Inc. Laboratory. RESULTS CONTINUED Sole Supports, Inc.. spends $500,000 annually to ship foam casting boxes to their clients. Clients cast the arch of their patients’ feet in the foam and then send a scan of the cast via the Internet to Sole Supports, Inc.. for manufacturing of the patients’ custom foot orthotics. The foam material currently used for casting can only be utilized once and then must be thrown out. Our project is to develop a reusable casting apparatus that: 1. Maintains Sole Supports, Inc.'s casting technique 2. Easily returns to its original shape 3. Is cost effective 4. Is environmentally friendly 1. Generate List of Possible Reusable Casting Materials 2. Research and Select Most Promising Reusable Casting Materials for Testing 3. Test Memory Foam Properties 4. Build and Test Prototypes 5. Conduct an Economic Analysis Investigation of Memory Foam Properties: Memory Foam Type Gree n Gree n Yello w Yello w Pin k Pin k Temperature (°F) 72 47 72 49 72 NA 30 Second Depression Retraction Time (s) 9 6.6 6.5 11 31 NA 60 Second Depression Retraction Time (s) 9 3 8 8.8 33 NA After testing several different prototypes it was concluded the dual-compartment sandbox system (Prototype F) is the least expensive casting method that maintains the requirements for Sole Support, Inc.’s casting technique. It is easily reusable. All materials used to construct the dual-compartment sandbox system (Prototype F) are inexpensive, can be found at a local home improvement store, and are recyclable. Therefore, all of the project objectives have been achieved with the dual-compartment sandbox system (Prototype F). Sand can get messy, especially when transporting it from the bottom catch box back to wire grated top box. • Readjust catch-box size • Use a funnel to minimize spilling Moisture levels in sand should be measured and standardized • If sand is too dry the shape of the foot cannot be maintained • If sand is too wet the sand compacts too much to cast the foot 1 “Corrective Paradigm: Mass Position” http://www.solesupports.com/visitorhome/theoryandresearch.apsx 2 Dr. Stu Currie, “Advancements in Custom Orthotics” http://www.solesupports.com/visitorhome/theoryandresearch.apsx 3 http://www.solesupports.com Economic Analysis: • Changes in retraction time due to decreases in temperature were inconclusive because water caused memory foam to loose its memory capabilities R yan's Footand Body W eight 0 10 20 30 40 50 60 70 0 10 20 30 40 50 60 D epression Tim e (s) R etraction Tim e (s) CONCLUSION FUTURE WORK REFERENCES ACKNOWLEDGEMENTS E. Moist Sand Piled in the Center of a Wooden Box • Captured and held foot shape and arch height • Sand displaced laterally under applied force 3D Scans: Left: Sand cast Right: Sole Supports, Inc. current foam cast F. Moist Sand in a Dual-Compartment Wooden Box System • Captured and held foot shape and arch height. • Sand displaced vertically into bottom catch box under applied force • Depth of cast increased due to reduction in sand compaction Prototype Testing Continued: • Retraction time increases as time of applied force increases and density of memory foam increases BACKGROUND ABSTRACT PURPOSE METHODS Introduction • Sole Supports, Inc. spends ~$500,000 annually to ship their foam casting box • Goal: Develop an economically advantageous reusable casting apparatus • Methods • Design and test a number of different casting devices • Brainstorm a number of solutions; perform research on these solutions • Build and test a number of prototypes • .Finalize sand design and test the device using Sole Supports, Inc.’s laser scanners to verify the effectiveness of our design Results and Conclusion • Building and testing a number of our designs we were able to conclude that there were many limitations to the memory foam and modeling clay designs • Dual-compartment sandbox system had limited problems and proved to satisfy all of the objectives that were set forth for this project, resulting in a successful design of a reusable casting apparatus Foot Orthotics • Support the arches of the patient’s feet • Correct the function of the foot muscles • Used with patients suffering from collapsed arches caused by aging or disease MASS Position Theory • Maximum Arch Supination Stabilization • Deficient supination of the foot arch during midstance to forefoot loading 1 Full Contact Orthotics • Remain in full contact with the arch at all times throughout the gait cycle. 2 Gait Referenced Casting • Follows the biomechanics of the foot as if the patient were going through their normal gait cycle. 3 Foot Orthotic MASS Position (grey) Neutral Position (red) Full Contact Orthotic Gait Reference d Casting • Total Saving: $543,000 • Must use dual-compartment sandbox system 4 times to break even Sole Supports, Inc. Foam Casting Boxes Materials Cost/Unit Annual Boxes $2.45 $73,487 Foam $0.92 $27,595 Shipping $16.00 $480,000 Total $19.37 $581,082 Dual-Compartment Sandbox System Materials Cost/Unit Annual Labor $20.00 $10,000 Sand $5.00 $2,500 Hardware $30.00 $15,000 Shipping $20.00 $10,000 Total $75.00 $37,500
description
Memory Foam Density:. >. >. Foot Orthotic. MASS Position (grey) Neutral Position (red ). Full Contact Orthotic. Gait Referenced Casting. Development of a Reusable Casting Apparatus for Custom Made Foot Orthotics Keegan Compton, Ryan Cook, Michelle Sauer - PowerPoint PPT Presentation
Transcript of Memory Foam Density:
Ryan's Foot and Body Weight
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Prototype Testing:
B. Memory Foam with Ziploc Bag• Held the shape of a square wooden block after air was removed• Rounded edges were not desired by Sole Supports, Inc.
C. Play-Doh in Rubbermaid Container• Captured and held the foot shape and arch height• Very dense, required lots of applied force to cast the foot• Play-Doh stuck to patient’s foot after casting
D. Moist Sand in Sole Supports, Inc. Casting Box• Captured and held the foot shape and arch height• Depth of cast limited due to sand compaction• Scan of sand cast met Sole Supports, Inc. specifications
A. Memory Foam with Latex Exterior and Check Valve• Memory foam absorbed liquid latex instead of creating a vacuum tight exterior layer
Development of a Reusable Casting Apparatus for Custom Made Foot Orthotics
Keegan Compton, Ryan Cook, Michelle SauerBiomedical Engineering, Vanderbilt University, Nashville, TN 37235
Sole Supports, Inc., Lyles, TN 37098
RESULTS
Special thanks to Dr. Paul King, Mr. Matt Moore, Dr. Hak-Joon Sung, and Mr. Brad Compton for their help with this project. We also appreciate the support of the Vanderbilt Biomedical Engineering Department and Sole Supports, Inc. Laboratory.
RESULTS CONTINUED
Sole Supports, Inc.. spends $500,000 annually to ship foam casting boxes to their clients. Clients cast the arch of their patients’ feet in the foam and then send a scan of the cast via the Internet to Sole Supports, Inc.. for manufacturing of the patients’ custom foot orthotics. The foam material currently used for casting can only be utilized once and then must be thrown out. Our project is to develop a reusable casting apparatus that:
1. Maintains Sole Supports, Inc.'s casting technique2. Easily returns to its original shape3. Is cost effective4. Is environmentally friendly
1. Generate List of Possible Reusable Casting Materials2. Research and Select Most Promising Reusable Casting Materials for Testing3. Test Memory Foam Properties4. Build and Test Prototypes5. Conduct an Economic Analysis
Investigation of Memory Foam Properties:
Memory Foam Type Green Green Yellow Yellow Pink Pink
Temperature (°F) 72 47 72 49 72 NA
30 Second DepressionRetraction Time (s) 9 6.6 6.5 11 31 NA
60 Second DepressionRetraction Time (s) 9 3 8 8.8 33 NA After testing several different prototypes it was concluded the dual-compartment
sandbox system (Prototype F) is the least expensive casting method that maintains the requirements for Sole Support, Inc.’s casting technique. It is easily reusable. All materials used to construct the dual-compartment sandbox system (Prototype F) are inexpensive, can be found at a local home improvement store, and are recyclable. Therefore, all of the project objectives have been achieved with the dual-compartment sandbox system (Prototype F).
Sand can get messy, especially when transporting it from the bottom catch box back to wire grated top box. • Readjust catch-box size• Use a funnel to minimize spilling
Moisture levels in sand should be measured and standardized
• If sand is too dry the shape of the foot cannot be maintained• If sand is too wet the sand compacts too much to cast the foot
1 “Corrective Paradigm: Mass Position” http://www.solesupports.com/visitorhome/theoryandresearch.apsx
2 Dr. Stu Currie, “Advancements in Custom Orthotics” http://www.solesupports.com/visitorhome/theoryandresearch.apsx
3 http://www.solesupports.com
Economic Analysis:
• Changes in retraction time due to decreases in temperature were inconclusive because water caused memory foam to loose its memory capabilities
Ryan's Foot and Body Weight
010203040506070
0 10 20 30 40 50 60
Depression Time (s)
Ret
ract
ion
Tim
e (s
)
CONCLUSION
FUTURE WORK
REFERENCES
ACKNOWLEDGEMENTS
E. Moist Sand Piled in the Center of a Wooden Box• Captured and held foot shape and arch height• Sand displaced laterally under applied force
3D Scans:Left: Sand castRight: Sole Supports, Inc. current foam cast
F. Moist Sand in a Dual-Compartment Wooden Box System• Captured and held foot shape and arch height.• Sand displaced vertically into bottom catch box under applied force• Depth of cast increased due to reduction in sand compaction
Prototype Testing Continued:• Retraction time increases as time of applied force increases and density of memory foam increases
BACKGROUND
ABSTRACT
PURPOSE
METHODS
Introduction• Sole Supports, Inc. spends ~$500,000 annually to ship their foam casting box• Goal: Develop an economically advantageous reusable casting apparatus
• Methods• Design and test a number of different casting devices• Brainstorm a number of solutions; perform research on these solutions• Build and test a number of prototypes• .Finalize sand design and test the device using Sole Supports, Inc.’s laser scanners to
verify the effectiveness of our design
Results and Conclusion• Building and testing a number of our designs we were able to conclude that there were
many limitations to the memory foam and modeling clay designs• Dual-compartment sandbox system had limited problems and proved to satisfy all of
the objectives that were set forth for this project, resulting in a successful design of a reusable casting apparatus
Foot Orthotics• Support the arches of the patient’s feet • Correct the function of the foot muscles• Used with patients suffering from collapsed arches caused by aging or disease
MASS Position Theory• Maximum Arch Supination Stabilization• Deficient supination of the foot arch during midstance to forefoot loading 1
Full Contact Orthotics• Remain in full contact with the arch at all
times throughout the gait cycle.2
Gait Referenced Casting• Follows the biomechanics of the foot as if
the patient were going through their normal gait cycle. 3
Foot Orthotic
MASS Position (grey)
Neutral Position (red)
Full Contact Orthotic
Gait Referenced Casting
• Total Saving: $543,000• Must use dual-compartment sandbox system 4 times to break even
Sole Supports, Inc. Foam Casting Boxes Materials Cost/Unit Annual
Boxes $2.45 $73,487 Foam $0.92 $27,595 Shipping $16.00 $480,000 Total $19.37 $581,082
Dual-Compartment Sandbox SystemMaterials Cost/Unit Annual
Labor $20.00 $10,000 Sand $5.00 $2,500 Hardware $30.00 $15,000 Shipping $20.00 $10,000 Total $75.00 $37,500
