Summary of Replies: Shaping Foam Covers
Braceon CPO
Description
Collection
Title:
Summary of Replies: Shaping Foam Covers
Creator:
Braceon CPO
Text:
Original question:
>>>Has anyone found an easy way to shape the bulk of the foam from soft
prosthetic covers, without the cost and use of a band saw, or excessive
grinding and sanding? Someone had once suggested using an inexpensive
(kitchen) electric carving knife.
Any techs with tips out there?<<<
Thanks to all who responded. Everyone had great suggestions. It seems the
electric carving knife is a very popular prosthetic lab. tool.
Responses:
I suggest you use the IPOS carver or soft foam shaper, #0429. It has a
foam core and a series of steel brushes sticking out that help the carving
go pretty fast and safe. Don't use a bandsaw. You might inadvertently cut
into something that you didn't intend.
-------------
BR, I have found using the Otto Bock 6R8 covers fabricated of Plastizote
shape well with a regular kitchen Knife, the other, softer covers such as the
6R6 may be quick shaped with an electric knife or a wire wheel. Obviously,
the electric knife makes less mess.
Joe Perry CP
---------------
We still utilize the electric carving knife in our facility and use the
Troutman for the final grinding. This method is the least expensive and
provides good end results. Other options that you may want to consider are
pre-shaped covers or heat formable sheets.
Carrie Melton CP
-----------
in my experance a very sharp shiving knife works well to get the bulk off
but sanding will still be needed
----------
Yes, an electric carving knife works very well. Pinch an inch or so between
your index finger and thumb and gently pull away from the socket. you'll
have to develop a touch as to how much tension to pull, (too much and you'll
cut right through), but the knife works quite well.
Jeff McDonald
------------
In the past I have used the electric carving knife but became frustrated
when the knife was dull, tried to sharpen the blades but didn't work to good
after that. Now I use a wire wheel on the grinder very fast but makes some
what of a mess. Even used a hot wire, but that smoked the whole place out.
Try the wire wheel on a grinder if you have one.
Gary
---------
Yes, our techs use an electric carving knife. If you're really cheap, you may
be able to find a used knife at a second hand store like goodwill or
salvation army.
----------
I use a hacksaw blade. Use it in such a way that the cut stroke is the pull.
(it just gives you a little more control than trying to push through the
cover. It also helps to wrap a little tape of some kind around the blade
where you will hold it. It's cheap and I think I've been using the same
blade for a year.
Brian. W (O&P Tech)
------------
Yes, get an electric carving knife. They work great and they're
reasonably inexpensive!
Former tech and current prosthetic practitioner student
Matt Green
----------
Yes, one of our Tech uses an electric kitchen carving knife to pre-shape
the foam. The other Tech just uses a long blade, non-serrated knife and saws
the excess off the cover. Both ways to work fine.
Goodluck.
RM
--------
The tip for using a carving knife is the best one. Our instructor here at
the OK state O@P program say that it works best. BGuthrie
------------
The electric knife works well. Play with some scraps first to get a feel. As
with any power tool, you want to let the knife do the cutting, pressure will
deform the foam, and the shape will not be what you planned.
---------
Buy a wire wheel and attach it to your grinder - it removes the foam
effortlessly. Maybe TOO effortlessly!
If you have a socket carver (Trautman) you can mount a wheel on it and you'll
have much better access than you'll get from a grinder. I'd suggest a
smaller 5 wire wheel for this use, since they are not always well balanced
and the smaller wheel will vibrate less.
About electric carving knives: I've used some that worked great and others
that were unusable - I never could figure out what caused the great
difference between them . Take a piece of foam to your local thrift store -
they will probably have a selection of electric carving knives for you to
try.
Daniel Watkins MS CPO
O&P Technician Program
Francis Tuttle Technical Center
12777 North Rockwell
Oklahoma City, OK 73142
Phone: 405 717 4199
Fax: 405 717 4788
<URL Redacted>
<Email Address Redacted>
-----------
Electric knives have been used for years by myself and other collegues I
know.
It's the quickest way I know of.
Just like carving the Sunday roast!
Alan Kercher
---------------
Most C-fab centers will carve your foam outer cosmetic shape for you. I
recommend a tracing AP & ML with multiple circumferences and add 1/4 inch to
AP & ML measurements and 1/2 inch to all circ. measurements. Then you can
touch it up with your router later. No Band saw needed. Also if you are
really into doing it all yourself a hand held electric meat carving knife
on certain types of foam works well, then router for touchup. Good luck.
Bob Brown, Sr., CPO, FAAOP
----------------
I use the blade of an electric knife by hand after fashioning a handle to
it. The blade needs to be very sharp but somewhat coarse, sharpened when
needed with a coarse stone wheel.
Aryeh
--------
hi, yes an ele. carving works great thats all i've ever used. Learned that
from an old guy i worked for years ago. Debbi
-------
Electric kitchen knives do work if you pull the extra foam away from the limb
as you cut it away. Don't pull too hard or you can distort the cover and cut
away too much. I always preferred to use ball shaped rasp for the trautman.
It really doesn't take any longer and the possibility of taking too much off
is reduced if you get your general shape and then reduce to size. Good
luck:) Jeremy Livingston, O&P prac. student
------------
********************
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the words UNSUB OANDP-L in the body of the
message.
If you have a problem unsubscribing,or have other
questions, send e-mail to the moderator
Paul E. Prusakowski,CPO at <Email Address Redacted>
OANDP-L is a forum for the discussion of topics
related to Orthotics and Prosthetics.
Public commercial postings are forbidden. Responses to inquiries
should not be sent to the entire oandp-l list.
>>>Has anyone found an easy way to shape the bulk of the foam from soft
prosthetic covers, without the cost and use of a band saw, or excessive
grinding and sanding? Someone had once suggested using an inexpensive
(kitchen) electric carving knife.
Any techs with tips out there?<<<
Thanks to all who responded. Everyone had great suggestions. It seems the
electric carving knife is a very popular prosthetic lab. tool.
Responses:
I suggest you use the IPOS carver or soft foam shaper, #0429. It has a
foam core and a series of steel brushes sticking out that help the carving
go pretty fast and safe. Don't use a bandsaw. You might inadvertently cut
into something that you didn't intend.
-------------
BR, I have found using the Otto Bock 6R8 covers fabricated of Plastizote
shape well with a regular kitchen Knife, the other, softer covers such as the
6R6 may be quick shaped with an electric knife or a wire wheel. Obviously,
the electric knife makes less mess.
Joe Perry CP
---------------
We still utilize the electric carving knife in our facility and use the
Troutman for the final grinding. This method is the least expensive and
provides good end results. Other options that you may want to consider are
pre-shaped covers or heat formable sheets.
Carrie Melton CP
-----------
in my experance a very sharp shiving knife works well to get the bulk off
but sanding will still be needed
----------
Yes, an electric carving knife works very well. Pinch an inch or so between
your index finger and thumb and gently pull away from the socket. you'll
have to develop a touch as to how much tension to pull, (too much and you'll
cut right through), but the knife works quite well.
Jeff McDonald
------------
In the past I have used the electric carving knife but became frustrated
when the knife was dull, tried to sharpen the blades but didn't work to good
after that. Now I use a wire wheel on the grinder very fast but makes some
what of a mess. Even used a hot wire, but that smoked the whole place out.
Try the wire wheel on a grinder if you have one.
Gary
---------
Yes, our techs use an electric carving knife. If you're really cheap, you may
be able to find a used knife at a second hand store like goodwill or
salvation army.
----------
I use a hacksaw blade. Use it in such a way that the cut stroke is the pull.
(it just gives you a little more control than trying to push through the
cover. It also helps to wrap a little tape of some kind around the blade
where you will hold it. It's cheap and I think I've been using the same
blade for a year.
Brian. W (O&P Tech)
------------
Yes, get an electric carving knife. They work great and they're
reasonably inexpensive!
Former tech and current prosthetic practitioner student
Matt Green
----------
Yes, one of our Tech uses an electric kitchen carving knife to pre-shape
the foam. The other Tech just uses a long blade, non-serrated knife and saws
the excess off the cover. Both ways to work fine.
Goodluck.
RM
--------
The tip for using a carving knife is the best one. Our instructor here at
the OK state O@P program say that it works best. BGuthrie
------------
The electric knife works well. Play with some scraps first to get a feel. As
with any power tool, you want to let the knife do the cutting, pressure will
deform the foam, and the shape will not be what you planned.
---------
Buy a wire wheel and attach it to your grinder - it removes the foam
effortlessly. Maybe TOO effortlessly!
If you have a socket carver (Trautman) you can mount a wheel on it and you'll
have much better access than you'll get from a grinder. I'd suggest a
smaller 5 wire wheel for this use, since they are not always well balanced
and the smaller wheel will vibrate less.
About electric carving knives: I've used some that worked great and others
that were unusable - I never could figure out what caused the great
difference between them . Take a piece of foam to your local thrift store -
they will probably have a selection of electric carving knives for you to
try.
Daniel Watkins MS CPO
O&P Technician Program
Francis Tuttle Technical Center
12777 North Rockwell
Oklahoma City, OK 73142
Phone: 405 717 4199
Fax: 405 717 4788
<URL Redacted>
<Email Address Redacted>
-----------
Electric knives have been used for years by myself and other collegues I
know.
It's the quickest way I know of.
Just like carving the Sunday roast!
Alan Kercher
---------------
Most C-fab centers will carve your foam outer cosmetic shape for you. I
recommend a tracing AP & ML with multiple circumferences and add 1/4 inch to
AP & ML measurements and 1/2 inch to all circ. measurements. Then you can
touch it up with your router later. No Band saw needed. Also if you are
really into doing it all yourself a hand held electric meat carving knife
on certain types of foam works well, then router for touchup. Good luck.
Bob Brown, Sr., CPO, FAAOP
----------------
I use the blade of an electric knife by hand after fashioning a handle to
it. The blade needs to be very sharp but somewhat coarse, sharpened when
needed with a coarse stone wheel.
Aryeh
--------
hi, yes an ele. carving works great thats all i've ever used. Learned that
from an old guy i worked for years ago. Debbi
-------
Electric kitchen knives do work if you pull the extra foam away from the limb
as you cut it away. Don't pull too hard or you can distort the cover and cut
away too much. I always preferred to use ball shaped rasp for the trautman.
It really doesn't take any longer and the possibility of taking too much off
is reduced if you get your general shape and then reduce to size. Good
luck:) Jeremy Livingston, O&P prac. student
------------
********************
To unsubscribe, send a message to: <Email Address Redacted> with
the words UNSUB OANDP-L in the body of the
message.
If you have a problem unsubscribing,or have other
questions, send e-mail to the moderator
Paul E. Prusakowski,CPO at <Email Address Redacted>
OANDP-L is a forum for the discussion of topics
related to Orthotics and Prosthetics.
Public commercial postings are forbidden. Responses to inquiries
should not be sent to the entire oandp-l list.
Citation
Braceon CPO, “Summary of Replies: Shaping Foam Covers,” Digital Resource Foundation for Orthotics and Prosthetics, accessed November 5, 2024, https://library.drfop.org/items/show/217958.
