Archive for category: News

Assessment

The podiatrist goes through the medical history of the patient, discussing any conditions or injuries the patient previously encountered that may be contributing factors to any current conditions. The podiatrist begins the lower extremity biomechanical assessment. This includes orthopaedic assessment and clinical gait analysis. This is followed by a review of footwear with recommendations advanced based on lifestyle and activities. Finally, a 3 dimensional impression of the patient’s foot is captured or what is known as a ‘Anatomical Volumetric Foot Model’ [AVFM]. This is a physical or digital model that captures a person’s three dimensional plantar foot anatomy when the foot is non weight-bearing, semi weight-bearing and fully weight-bearing.

Foot Modelling

A digital AVFM must use actual 3 dimensional data points taken directly from the foot to duplicate plantar foot anatomy. The most common examples include laser 3D scanners, stereo-digital 3D imaging systems and pin array systems. A physical AVFM captures the foot anatomy through direct contact to duplicate plantar foot anatomy. The most common examples see plaster of paris casts used or foam impressions taken directly from the foot. Any material or method that uses direct capture of the entire plantar foot anatomy creates an AVFM.

Plaster of paris foot casting

Manufacturing the Orthotic

Firefly Orthoses only accepts ‘Anatomical Volumetric Foot Models’ and all our prescription orthoses conform to this classification ahead of the manufacturing process.

Firefly will receive a prescription document from the Podiatrist, detailing all relevant information about the patient [weight, activity level, medical condition and footwear] along with either a physical or digital AVFM ahead of manufacturing the anatomical custom foot orthotic [ACFO]. The shell of the device is the foundation around which the device is created. The device’s shell is made from thermoplastics such as Polypropylene or Copolymer, Nylon reinforced thermoplastic, Carboplastic or Carbon Fibre. Each of these materials have unique characteristics that will benefit the patient depending on their needs.

There are two primary methods of orthotic shell manufacturing:

1. direct milled devices milled from polypropylene plastic,
2. vacuum press, where the shell is moulded using a vacuum press from carbon fibre or carbon plastics including: polypropylene, copolymer, carbon graphite or laminate resin with EVA.

The direct milled process sees the orthotic device fashioned from a block of the chosen shell material usually a Thermoplastic such as Polypropylene. From here the device is machine sculpted and shaped to meet the patient’s needs. This method is suitable for durable, long-lasting devices that accommodate all modifications.

The vacuum press method sees the heated shell material placed over the positive cast model, and moulded around the model using a vacuum press. This method allows for a variety of shell materials such as copolymer, XT Sprint or TL2100. Devices manufactured via this process are generally lightweight, offering greater flexibility and suitable for dress wear and sports wear such as football boots. Depending on the style of orthoses, there are limitations to the modifications that can be made to the vacuum pressed device.

The process of finishing the orthoses is a combination of computer aided design and manufacturing, coupled with craftsmanship. Firefly Orthoses’ highly skilled technicians finish the orthotic devices to exceptional standards.

Our technicians not only shape the orthoses to meet the contours of the foot, but further modify using postings, padding and additions to ensure the foot is balanced through the gait cycle. The finished device must meet the design requirements as specified by the prescribing physician, taking into consideration appropriate medial and /or lateral arch fill, lateral column expansions, heel expansion, and intrinsic forefoot and or rear-foot corrections.

 

 

Cast, positive mold and orthotic.

The image above shows a plaster of paris cast of the patient’s foot, followed by a positive mould of the cast and finally the finished custom made Firefly Orthotic Device.

The combination of materials, additions and modifications available to meet the patient’s needs can be viewed on our products page, and are combined alongside a suitable top cover material of either EVA, expanded vinyl, neoprene, open and closed cell polyurethane, cork and leather.

Firefly Orthoses Fit

The custom-made orthoses designed and manufactured by Firefly ensure enough flex for functional pronation and comfort and enough stiffness to maintain arch height for normal function.

Finished Orthotic

Firefly Orthoses wearer, Georgie Hermitage bettered her T37 400-metre World Record at the IPC Grand Prix in London recently. 26 year-old Georgie beat her previous World Record set in Berlin on June 20th, crossing the line in London’s Olympic Stadium in a time of one minute 2.48 seconds. Her new time shaved .22 of a second of her previous record. Georgie competes in the T37 400m event. The International Paralympic Committee allocates the T37 classification for athletes with athetosis, ataxi and/or hypertonia. She is also a member of the women’s 4X100m GB squad.

— IPC Athletics (@IPCAthletics) July 27, 2015

Georgie has Cerebral Palsy, but the condition is only evident on close inspection. She is a patient of Katrina Waller, Clinical Lead and Podiatrist at Compleet Feet in Sussex. On her clinic blog, Katrina outlines that following a biomechanical assessment she could see how the condition was effecting Georgie’s running. Katrina outlines how Cerebral Palsy impacts Georgie’s movement; ‘… there being some muscle weakness and reduced muscle build on the left, but this does not slow her down or affect the quality of her life, far from it. She has found she can run better than many athletes’.

As her Podiatrist, Katrina identified a ‘tightness of her tendo-achilles and calf muscles meaning she has a functional shorter leg, with the foot tending to roll inwards. What we term over-pronation. Georgie is having to work the left lower limb hard to compensate, and the right side takes a lot of the strain. Not an ideal situation if you are trying to run super efficiently’. Georgie wears prescription Firefly orthoses in her running shoes. The orthoses are custom-designed to support Georgie’s foot to prevent over-pronatory stress. Katrina describes the benefit of Firefly Orthoses, ‘they allow Georgie run like an athlete, keep up with the high training demands placed upon her, helping her to secure her place to run in the 2016 Rio Paralympics’. You can read Katrina’s full blog post on Georgie here. Georgie intends to represent Great Britain at the IPC European Championships in Swansea in August as she builds towards her goal of competing for a medal at Rio 2016. All at Firefly Orthoses are wishing Georgie the best of luck and continued success!

Firefly have partnered with SOLS, the company whose 3D printed orthoses are challenging traditional approaches to the design and manufacture of orthotic devices. Operating out of New York, SOLS’ disruptive technology is seeking to positively influence how podiatrists interact with their patients by embracing enhancements in technology. Just three photos [arch, heel and ankle] captured using Apple’s iPhone or iPad is all that’s required to accurately map the key anatomical features of an individual’s unique foot and gait. Speed, efficiency and most importantly accuracy are at the heart of this process.

In keeping with traditional expectations, patient specifications and requirements are then applied to the digital model. From here it is customised for shoe type, patient weight, activity and foot flexibility. The customised digital model is then closely inspected by biomechanical and 3D engineers. The next stage sees the model become reality.  Laser sintered from aerospace grade Nylon plastic, the device is 3D printed printed to an accuracy of 5 microns. As an industry leader Firefly is constantly seeking new opportunities and practices to support the Podiatric profession.  Firefly’s partnership with SOLS is another example of how we are progressing Podiatry.  By engaging accessible technologies such as Apple’s iPhone and iPad, combining these with 3D modeling and printing software, we are delivering the future of Podiatry today. Register your interest in SOLS, email [email protected] today.

We’re embracing social media here at Firefly and we’d encourage you to ‘follow’, ‘like’ and ‘share’ with us across our various platforms. We’ll be posting news regularly on our website about our products, events and related topics. You can interact with us, posting questions, queries and comments about Firefly and our services to our various social media accounts. We’re always eager to hear your opinions. We’ll endeavour to provide you with informative content, relevant to the Podiatric profession. We’re always exploring new technologies and techniques that will enhance your ability to meet the needs of your patients. See our recent news item where Firefly’s medical director Martin Mc Geough demonstrated Sharp Shape’s 3D scanning technology in a clinic environment. Follow the links below to view our social media accounts. Firefly Orthoses on Facebook Firefly Orthoses on LinkedIn Firefly on Twitter