Thermoplastic Guide

7) Place the socket on the socket post and
use a hand cutter or drill press cutter to mill
the out side surface parallel to the inside
socket surface. This step is essential to
reduce stress and shear forces on the puck
and connecting bolts.
8) Place the socket
on the side hole
Jig and secure it
with the center
bolt and nut.
Drill out the
side hole for the
valve (AIRPUCK
ONLY). Use 3/4”
plastic bit.
8
1) Bond dummy in correct alignment onto the
flattened surface of the distal end of the model.
(see Model prep guide) Drill hole all the way
through the model so vacuum can reach the top
of the molding dummy. Address the transition
between the dummy and model. See model prep
and distal end guide for options.
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2) Install socket cap screws into the Thermo
Dummy. Thread all the way down so the screws
stand 1/4 inch off of the bottom of the dummy
(this will help establish an even 1/4 distal socket
thickness).
7
7
8
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9) Install AirPuck OR SmartPuck.
TM
No Tooling Thermo Fab
TM
3) Pull Thermoplastic socket. Pull the plastic
directly against the molding dummy. No nylons
should be used over molding dummy. Plastic
must be an excellent pull with perfect contact
around the molding dummy body. This is
the sealing surface. It is critical the plastic
conforms to the side wall of the dummy and
is smooth on the interior. Pull socket with
Thermolyn or Surlin type material. Use a flat disk
to compress the distal end of the pulled plastic.
1
4) Grind the plastic down to the socket cap screws. Keep distal surface
parallel to the dummy surface.
5) Drill push plate recess with the
PDI Push plate guide.
5) Mark and drill the side hole (AIRPUCK ONLY)
with a 3/4” plastic bit. Split the difference
between adjacent cap screws and draw a
bisection line up the side of the molding
dummy. Measure up 11mm from the base of
the molding dummy (distal end).
6) Insert PDI Push Plate.
7) Install the FET-SmartPuck
thermoforming dummy
(Designed for foam extraction
tooling.)
5
8) Use the center hole guide and
drill the center air hole through
the model. Thermoform the
socket. If nylons are used over
model, tuck them under the
FET Dummy.
6) Install AirPuckTM OR SmartPuck.TM
Cad Fabrication
1) Rectify Model with established
vacuum modifications. Save
Model.
2
2) Add a 1mm (high) X
68mm(wide) extension to the
bottom of the model. Save
Model.
1
4) Carve Model.
7
6
8
2
3) Add a 15mm (high) X 57mm
(wide) extension to the previous
extension. Save Model.
3
5
5280 PROSTHETICS, LLC
Puck
Thermoplastic
Guide
1501 WEST CAMPUS DRIVE, SUITE J | LITTLETON, CO 80120
3
4
1(800) 460-0288 | www.5280Prosthetics.com | www.Smartpuck.net
Copyright ©2013 by 5280 Prosthetics, LLC • Patent Pending • Version 03/15/2013
5280 PROSTHETICS, LLC | 1-800-460-0288
Rules of the game:
Thermoplastic Fab with PDI® Tooling
1) Nothing touches or contacts the molding dummy (no nylons, build ups,
foam etc. This is the surface in which the puck will seal against).
2) The plastic pull must be perfect with excellent vacuum (drill a hole all
the way through the model so vacuum gets to the distal end).
3) The interior of the void must be glass smooth.
4) The socket must be fabricated such that the dummy can be removed
(and the puck installed).
NOTE: For Thermoplastic check sockets we
strongly recommend Thermolyn Stiff (Otto
Bock) or similar. These materials are more
durable with less chance of failure.
Because of the drop in nature of the SmartPuckTM and AirPuckTM systems,
it is often necessary to fill the gap between the molding dummy and
the model.
This can be accomplished pre-fabrication by one of the following:
1) U
sing a flexible inner socket.
2) M
olding a distal pad prior to fabrication.
OR Accomplished post-fabrication by filling the gap with plaster and
one of the following:
1) U
sing the 5280 distal end injection tool.
2) F orming a fast setting silicone putty ring and placing it in the distal
socket while the patient bears weight in the prosthesis.
See the model prep and distal end guide for more information.
2) Pull Thermoplastic socket. Pull the plastic
directly against the molding dummy.
No nylons should be used over molding
dummy. Plastic must be an excellent pull
with perfect contact around the molding
dummy body. This is the sealing surface.
It is critical the plastic conforms to the
side wall of the dummy and is smooth
on the interior.
1) Bond dummy in correct alignment onto
the flattened surface of the distal end of
the model. (see Model prep guide) Drill
hole all the way through the model so
vacuum can reach the top of the molding
dummy. Address the transition between
the dummy and model. See model prep
and distal end guide for options. This air
hole will serve as the centering hole for
thermoplastic tooling.
4
4) Break out model or extract model. Widen center hole with a 3/8” step bit.
2
3) Drill a hole back up through the predrilled
air hole at the bottom of the model with a
long 1/4 drill bit. This is the centering hole
for the Euro
four hole
drill guide.
1
3
4
5
5
5) Place the four hole drill guide in the distal end
of the socket. Orient the four hole pattern as
desired. Tighten the center bolt to secure the
guide in place.
3
6) Drill out the four hole pattern. Be sure to keep
the drill bit straight so the pattern is not off set.
more>>>
5280 PROSTHETICS, LLC
6
1501 WEST CAMPUS DRIVE, SUITE J | LITTLETON, CO 80120
1(800) 460-0288 | www.5280Prosthetics.com | www.Smartpuck.net
Copyright ©2013 by 5280 Prosthetics, LLC • Patent Pending • Version 03/15/2013