Rotational moulding in the production of prostheses

The most developed of the possible prosthetic options available consists of a hollow tapered column having inserts at each end by which it is clamped through alignment couplings to the socket and foot respectively. For a below-knee application, the complete tapered column prosthesis weighs typically 1 kg. Static and fatigue testing of representative samples by the simultaneous application of compressive and bending loads to the maximum values specified by international standards exposed no failures by the time a million cycles had been reached. This method of fabrication has the merit of being capable of implementation locally on an “as required” basis. Additional advantages include the low cost of the mould tooling and the flexibility to mould a variety of shapes. Prosthetic feet are a possibility as are special shoes and orthotic parts. These may require other materials and experimentation is proceeding using structural and resilient foams. This paper discusses the place of rotational moulding in the provision of prosthetic shanks and shank sections. It covers the selection of thermoplastic material, the moulding conditions and their automation in a machine process, and the development of a suitable range of moulds. Also covered is the question of interfacing between the moulded shank sections and other limb components, fatigue strength as tested to date and early results of patient field trials.