Lesson 1Quality control checklist: fit, alignment, thickness, and finishThis section presents a structured quality control checklist for AFOs, covering fit, alignment, thickness, finish, hardware, and documentation, helping ensure safety, reproducibility, and readiness for patient fitting and follow-up.
Verifying alignment in all planesMeasuring wall thickness and consistencyInspecting edges, surfaces, and finishChecking joints, screws, and hardwareDocumenting findings and correctionsLesson 2Thermoforming fundamentals: heating, forming, and cooling protocolsThis section covers thermoforming science and protocols for AFO plastics, including heating profiles, drape and bubble forming, vacuum timing, cooling control, and safe handling to achieve consistent thickness and accurate contours.
Thermoplastic behavior and glass transitionOven setup, temperature, and timing controlDrape versus bubble forming indicationsVacuum timing, vents, and seal integrityControlled cooling and warpage preventionLesson 3Material selection: thermoplastic sheet gauges and composite layupsThis section reviews thermoplastic sheet gauges and composite layups for AFOs, explaining stiffness, weight, and fatigue behaviour, plus how to combine materials and orientations to meet specific biomechanical goals.
Comparing common AFO thermoplasticsSelecting sheet gauge by patient profileBasics of fiber orientation in compositesLayer stacking sequences and interfacesTesting samples for stiffness and flexLesson 4Vacuum forming and pressure forming techniquesThis section compares vacuum forming and pressure forming for AFO fabrication, outlining equipment setup, blister control, draw ratios, troubleshooting, and when to choose each method for different materials and patient presentations.
Vacuum forming workflow and key stepsPressure forming workflow and key stepsManaging draw, bridging, and webbingSeal quality, ports, and leak detectionChoosing a method for specific materialsLesson 5Weight-reduction strategies while maintaining strengthThis section explores strategies to reduce AFO weight while preserving strength and safety, including selective thinning, cutouts, material choice, and hardware optimisation, with attention to fatigue and patient function.
Identifying noncritical areas for reliefsDesigning structural windows and cutoutsOptimizing wall thickness distributionLightweight hardware and fastener choicesMonitoring fatigue and damage over timeLesson 6Shaping the calf section, ankle, and footplate to the modelThis section explains how to contour the calf shell, ankle region, and footplate to the positive model, optimising contact, reliefs, and lever arms while preserving alignment, comfort, and shoe compatibility for daily use.
Establishing reference lines on the modelContouring the calf section for contactShaping the ankle region for motion controlFootplate length, width, and rocker profileChecking symmetry and anatomical landmarksLesson 7Attaching padding, liners, straps, and closures securelyThis section details how to select, shape, and attach padding, liners, straps, and closures to AFOs, emphasising adhesion, screw placement, adjustability, and hygiene to maintain comfort and long-term device integrity.
Selecting padding and liner materialsAdhesives, primers, and surface prepStrap routing, length, and anchoringInstalling buckles, loops, and closuresMaintenance and replacement guidelinesLesson 8Adding reinforcement: struts, flanges, and hinge housings for articulated AFOsThis section explains how to design and integrate struts, flanges, and hinge housings into articulated AFOs, focusing on load paths, screw purchase, motion control, and durability while preserving adjustability and patient comfort.
Locating struts along functional load linesDesigning flanges for stiffness and comfortReinforcing and blocking hinge housing areasFastener selection and screw purchase zonesAvoiding stress risers and crack initiationLesson 9Trimming, bevelling, and smoothing trim lines for comfort and functionThis section details how to mark, cut, bevel, and smooth trim lines on AFOs to balance comfort, clearance, and control, emphasising tool choice, edge geometry, and inspection to prevent skin irritation and pressure points.
Marking functional trim lines on the modelCutting techniques for clean, safe edgesBeveling edges for comfort and durabilityProgressive sanding and polishing methodsEdge inspection for hotspots and gaps
