casting & forming

CASTING & FORMINGPUR Foams ......................................................................................... 14

OKM Foams ......................................................................................... 18

Cast Bandages .................................................................................. 22

Casting Tools ...................................................................................... 24

Casting Boxes ..................................................................................... 25

Cast Cutters ........................................................................................ 28

Casting Interfaces .............................................................................. 30

Casting & Forming

14 .

asti op pur rigid FoamsPUR rigid foams with a wide range of applications in prosthetics and orthotics. Solutions for every application for the production of moulds and appliances with bulk densities of approx. 100-700Kg/m³.

Asti OP® H200 PU FoamFoam for deep drawn models and cosmetic coverings in prosthesis construction.

Density approx. 220Kg/m³, foaming factor approx. 5.0.

Mixing ratio: A:B = 100:100 parts by weight.

Code Size

TK1556 4.6Kg

TK1558 865g

Asti OP® H300 PU FoamFoam for deep drawn models and cosmetic coverings in prosthesis construction.



Code Size

TK1560 4.6Kg

TK1562 865g

Asti OP® H100 PU FoamVery light foam.



Code Size

TK1552 4.6Kg

TK1554 865g

Asti OP® H500 PU FoamLast foam for orthopaedic footwear. This material is nailable.



Code Size

TK1566 4.6Kg

TK1568 865g

TK1570 9.32Kg

Casting & Forming

15

Asti OP® H700 PU FoamUse for manufacturing very high mechanically stressed positive moulds and models, e.g. shoe lasts and tip additions. This material is nailable.



Code Size

TK1572 4.6Kg

TK1574 865g

TK1576 9.32Kg

Asti OP® Component BFor all Asti OP rigid foams.

Code Size

TK1546 4.6Kg

TK1548 865g

TK1550 9.32Kg

asti op pur rigid Foams

Asti S PUR-Flexible FoamOpen-cell flexible foam for the manufacture of larger individual paddings such as seats and arm supports. Density approx. 60Kg/m³, foaming factor approx. 15.

The fabricator can use the mixing ratio (in parts by weight) to adjust the Shore A hardness of the part to be foamed.

Mixing ratio:

A:B = 100:50 = Standard adjustmentA:B = 100:42 = Soft adjustmentA:B = 100:58 = Firm adjustment

Asti S should be mechanically stirred. Asti S is sensitive to cold and should not be stored at temperatures below 15°C. Shake thoroughly before use.

Code Description Size

TK1540 Asti S Component A 4.6Kg

TK1542 Asti S Component B 2.3Kg

TK1544 Asti S Component C 500g

AlgecastThe Algecast system is a two-part casting (foam & hardener) resin which is mixed together with a wooden spatula before pouring into the mould.

Expansion is equal to 1.7 times.


SF5310 Algecast 1.1kg

SF5312 Algecast 11.1kg

SF5318 Release Agent 0.86kg

Casting & Forming

16 .

AstiTech® 150 PU FoamFor the manufacture of forefoot replacement, flexible foam insoles, custom shoe bedding, seats and individual paddings.


Mixing ration: A:B = 100:50 parts by weight.

Code Size

TK1596 2.5Kg

TK1594 865g

AstiTech® 300 PU FoamFor the manufacture of forefoot replacement, flexible foam insoles, custom shoe bedding and individual paddings.



Code Size

TK1600 2.5Kg

TK1598 865g

AstiTech® 500 PU FoamFor the manufacture of forefoot replacement, flexible foam insoles, custom shoe bedding, seat shells and individual paddings.



Code Size

TK1504 2.5Kg

TK1502 865g

astitech pu FoamsThis open-cell, rub-resistant flexible foam has very high resilience for the manufacture of various padded parts. The Shore A hardness of the final product can be adjusted by the fabricator by pre-mixing different A components in the desired ratio.

AstiTech® Component BFor all AstiTech flexible foams. The B component is sensitive to cold and should not be stored at temperature below 15°C.

Code Size

TK1610 2.5Kg

TK1608 865g

TK1606 433g

Casting & Forming

17

alphaplast pur rigid FoamsAlphaPlast allows for optimal processing time, which enables adequate time from stirring to filling the mould. The formed parts do not shrink and have a very high heat distortion point.

AlphaPlast® H200 PU FoamFor stump embedding to convert the casting resin stump sleeve into a thick walled fitted part. Can also be used for hard compensations not subject to high stress, especially for greater length discrepancies.


Code Size

TK1580 4.6Kg

TK1578 865g

AlphaPlast® H300 PU FoamFor smaller highly stressed parts such as short leg compensations.


Code Size

TK1584 4.6Kg

TK1572 865g

AlphaPlast® H700 PU FoamImpact and nail resistant rigid foam, especially for orthopaedic shoe lasts and shoe forms as well as positive moulds in the entire orthopaedic range.


Code Size

TK1588 4.6Kg

TK1586 865g

AlphaPlast® Component BFor all AlphaPlast rigid foams.

Code Size

TK1592 4.6Kg

TK1590 865g

Casting & Forming

18

OKM Elax High absorption PU for insoles

OKM ELAX for PU insoles ideally suited to diabetic patients, poly arthritic patients and for patients who require substantial off-loading.

This material can also used for the manufacture of prostheses and insoles for toe amputations (in prostheses for patients with Chopart’s and Lis franc’s amputations, the fore-foot can be integrated into the insole or prosthesis).

Characteristics:

● Thanks to its expansion, this material is 50% lighter than other PUs used in insoles. ● Resistant to wear and tear. ● Allows an integral forefoot to be constructed into the insole.

Product 2kg 5kg 25kg

OKM ELAX LG3033 LG3035 LG3037

OKM ISO 180 LG3039 LG3041 LG3043

OKM DurRigid PU for lasts

Creates non-expansive, extremely hard polyurethane, developed for the manufacture of made-to-measure moulds for insoles and shoes and Chopart prosthesis etc.

● Corrections and reductions can be made using a grinding wheel. ● Additions may be made, where necessary, with plaster or mastic. ● Allows the application of staples and studs.

With the incorporation of OKM Micro F additive, moulds are lighter and easier to modify. Before filling the mould, OKM Desmold L must be applied so that the mould can be turned out correctly.


OKM DUR LG3051 LG3053 LG3057

OKM Micro F LG3059

OKM Desmold L LG3029

OKM ISO 110 LG3045 LG3047 LG3049

OKM Foam 200/300PU for making prosthesesBoth systems (200 and 300) have similar characteristics - they allow expansive polyurethane to be obtained and they have been conceived for the manufacture of prostheses in orthopaedics.

This polyurethane is obtained by mixing OKM Foam 200 or 300 with OKM ISO 110.

Before filling the mould, OKM Desmold L must be applied so that the mould can be turned out correctly.

● Rapid hardening. ● Easy to sand. ● Adheres well. ● Lighter than either wood or plaster.


OKM Foam 200 LG3075 LG3029 LG3079

OKM Foam 300 LG3081 LG3083 LG3085

OKM ISO 110 LG3045 LG3047 LG3049


okm pu Foams

Casting & Forming

19

Two systems with similar characteristics and applications with which an expansive polyurethane can be obtained for filling patient moulds (mainly corset moulds). Both products should be mixed with OKM ISO110.

● 80 - 90% lighter than conventional plaster moulds. ● Additions can be made using plaster. ● The polyurethane hardens in just a few minutes.

Before filling the mould, OKM DESMOLD L must be applied.

OKM 80/120PU for filling large corset moulds


OKM Foam 80 LG3087 LG3089

OKM Foam 120 LG3091 LG3093 LG3095

OKM ISO 110 LG3045 LG3047 LG3049


okm pu Foams

OKM CopyFlexible PU for copying prosthetic fittingsNon-expansive system that allows prosthetic fittings common in orthopaedics to be reproduced, without creating undue problems for the patient.

Use a mixture of OKM COPY with OKM ISO 170. Apply a layer of OKM Desmold F so that the mould can be turned out correctly.

● As this is a non-expansive PU, a faithful copy of the fitting can be obtained. ● Allows lamination previous to fitting the PVA cover.

Product 1 kg 1.5 kg 2 KG 5kg 25kg

OKM COPY LG3097

OKM ISO 170 LG3013 LG3015 LG3017

OKM Desmold F LG3027

OKM Flexfoam 80/110PU For making seatsPatients with disabilities, scoliosis and deformities with limited mobility require a correct seating posture in order to avoid excessive pressure, minimising the appearance of ulcers and sores, thus improving the patient’s quality of life.

● Allows filling to take place in various phases. ● Choice of colours and finishes. ● Adaptability and comfort. ● OKM Flex paint seals the unit and hides irregularities.

OKM Flexfoam 80 is normally used for children, OKM Flexfoam 110 for older children.

With OKM paint, the seat can be painted to achieve a suitable finish. This paint has been specifically developed for this PU.

Product 1.5 kg 2 kg 5 kg 25kg

OKM Flexfoam 80 LG3001 LG3003 LG3005

OKM Flexfoam 100 LG3007 LG3009 LG3011

OKM ISO 120 LG3019 LG3021 LG3023

OKM Desmold F LG3027

OKM Isolate C LG3031

OKM Flexpaint LG3025

Casting & Forming

20

Code Size Measurements

SX1130 XXS 35-41cm

SX1131 XS 41-47cm

SX1132 Small 46-53cm

SX1133 Medium 51-59cm

SX1134 Large 55-63cm

SX1135 X-Large 58-67cm

SX1136 XX-Large 61-71cm

OKM Knee OrthosisThis model is recommended for the following pathologies:

● Knee prosthesis postsurgical treatment ● Ligament Injuries ● Kneecap fractures ● Shinbone fractures

Code Description

SX1210 Rigid Foam 170






SX1216 Soft Foam 300





OKM Foam ResinsPolyurethane foams for use with OKM.

OKM is an immobilisation system which combines rigidity and comfort, utilising the combined properties of polyurethane foam and elastic 100% cotton cloth. The application process lasts less than 7 minutes, with the finished orthosis completely functional within 15 minutes.

Thanks to its zip system the patient can remove the orthosis to take care of the personal hygiene, move forward the rehabilitation exercises, monitoring the progress of the pathology and so on. The zip can be locked to avoid the removal of the orthosis by the patient.

okm system

Casting & Forming

21

OKM Dorsal - Lumber CorsetThis model is recommended for the following pathologies:

● Dorsal and lumbar spine fractures ● Osteoporosis ● Rheumatism ● Espondilolisis ● Postsurgical scoliosis treatment


SX1090 XXS 55-64cm

SX1091 XS 64-75cm







SX1150 XXXS 23-27cm

SX1151 XXS 26-30cm

SX1152 XS 29-33cm






OKM Accessories & Essentials

Code Description

SX1231 OKM Portable Mixer

SX1234 OKM Small Roller

SX1235 OKM Large Roller

SX1236 OKM Plastic Mixer

SX1242 OKM Steel Adaptor for Mixer

More OKM accessories are available, please contact us for further information.

OKM Orthosis BootThis model is recommended for the following pathologies:

● Shinbone and fibula fracture ● Aquiles pathologies ● Paralysis ● Joint rheumatism ● Ankle ligament injuries

okm system

Casting & Forming

22

Revive Synthetic Cast TapeAlternative to POP bandages for taking casts or for general orthopaedic use, Revive Cast is a synthetic tape which is manufactured from knitted fibreglass or polyester with water activated polyurethane resin. The fabric used in preparation of the roll is flexible in all directions which makes it very comfortable to use.

Code Size Colour

SW1600 5cm x 4m White

SW1605 7.5cm x 4m White



Code Size Colour





Code Size Colour





Polyester

Semi-Rigid Polyester

Fibreglass

Gefix POP BandagesPremium grade POP bandages for casting. Specially treated plaster spreads uniformly. Thick creamy texture when wet which allows for a smooth cast finish.

Code Size Per case

SF5208 7.5cm x 3m 80

SF5209 10cm x 3m 60

SF5211 15cm x 3m 40

SF5212 20cm x 3m 30

SF5218 15cm x 25m 1

Multicast POP BandagesMulticast POP Bandages combine quick setting, high grade plaster with a conformable and stable interlocked weave. The bandage has minimum plaster loss whilst the rich creamy texture allows easy handling.

These POP bandages are competitively priced for heavy users and those on tight budgets.

Code Size Per case

SF5262 7.5 x 2.7m 12

SF5264 10cm x 2.7m 12

SF5266 15cm x 2.7m 12

SF5268 20cm x 2.7m 12

synthetic cast tape

Casting & Forming

23,

Revive Under-PadFor use with synthetic tapes when used for orthopaedic use. This product does not require any additional cotton bandage due to the elasticity and the protective properties of the Under-Pad.

Revive Under-Pad has excellent wicking properties, absorbing moisture to prevent skin irritation. The material is also water resistant.

Code Size Colour






pop Bandages

STS Casting SocksIntended for use in moulding the foot for the purpose of making a shoe last (casting). It can also be used for duplicating (copying) an orthotic device for the foot, ankle or lower leg.

STS Casting Socks are made from a stretchy, fibreglass knit, which are impregnated with a water curable polyurethane resin. By exposing the material to water, a chemical reaction is initiated which causes the tubular moulding material in the STS Socks to become rigid.

Finished moulds or lasts made from the material are strong, lightweight and replicate the limb with great accuracy. The clinician using STS Copy Socks will find their use cleaner and quicker than traditional methods based on Plaster of Paris.

Slipper SockCode Size (UK)

SG1062 2 - 4

SG1063 5 - 8

SG1064 9 - 11

SG1065 12 - 14

Ankle SockCode Size (UK)

SG1030 2 - 4

SG1034 9 - 11

SG1036 12 - 14

Bermuda SockCode Size (UK)

SG1071 5 - 8

SG1072 9 - 11

SG1073 12 - 14

Sundries for Copy SocksCode Description

SG1050 STS Leg Lifter (with case)

SG1052 Plastic protective cutting strips

SG1055 Protective bags (100 per box)

Bemuda Sock Ankle Sock

Slipper Sock

Casting & Forming

24

Plaster Cast ScissorsHigh quality professional plaster scissors that are notched and rust proof.

Code SizeLA4618 22cm

Plaster Cast ShearsPlaster shears with spring mechanism.

Code SizeLA4609 22cm

Stille Plaster Shear 9 Inch (23cm) serrated upper blade. Stainless steel. Reusable, fully autoclavable.

Code SizeNV1120 23cm

scissors


Utility ScissorManufactured from stainless steel with a plastic handle, these all purpose scissors can cut through various materials of different densities and thicknesses.

Lister Bandage Scissors 7” Inch (18cm) tungsten carbide. Tungsten carbide, 24 carat gold plated handles. Stainless steel.

Code Size NV0075 18cm

Straight Jaw Dressing ScissorStainless steel.


Casting & Forming

25

Standard Impression Boxes Sold in packs of 25 boxes.

Code Depth

SA0451 40mm

SA0452 55mm

X-Large Impression Boxes Sold as pack of 6 boxes.

X-Large foot impression box fits up to size 15 foot.

Code Depth

SA0453 55mm

Code Size

SF5242 15kg Tub

SF5244 25kg Tub

Plaster of ParisFine Casting Plaster is a hemihydrate plaster (CaSO4.1/2 H2O) produced from naturally occurring gypsum mineral. We currently supply this product in poly tubs. This ensures safe transport and allows for a clean working environment.

plaster and alginate

Code Size

SF5241 10kg

Vermiculite Super Fine Filler for plasters and resins due to its bulking and lightening properties.

Alja-Safe® Alginate PowderSuitable for making moulds of body parts, Alja-Safe® Alginate Powder is easy to use and cures quickly. It is safe for use on human skin, reproduces fine detail and produces excellent temporary moulds.

Code Size:

RA3236 1.3Kg

Casting & Forming

26

Rasps - One Wire ‘Blade’Code Description Size

LA3544 Flat 280mm

LA3548 Round 300mm


LA3546 For Flat Rasp 280mm

LA3549 For Round Rasp 300mm

Replacement Blades

Flat File with RaspCode Description Size

LA3552 Flat 440mm


LA3558 For Flat Rasp 440mm

Replacement Blades

Surform ShaverCode Description

LA3550 Shaver with blade

LA3551 Replacement blade

Circular Rasp

Code Description

LA3445 Circular rasp with blade

LA3555 Replacement blade

cast rectiFication tools

Plaster Mixing Bowl Flexible bowl manufactured from natural rubber.

Code Size

LA2117 0.5 Litres

Casting & Forming

27

Wire BrushHeavy duty steel wire brush with stay-clean tough plastic handles and scraper attached. For removal of dirt and to prepare rough surfaces for application.

Code: Description:

LA3560 4 Rows

casting sundries

Casting PillowHelps create an accurate and reproducible model of the foot. The unique pillow shape and density allows the uncompensated foot to be suspended while maintaining neutral subtalar joint alignment as it bears load.

Code: Description

OG2019 Black

Code Description

SF5245 7 Inch

Indelible Writing PencilUsed for marking casts.

Wire BrushCode Description

LA3560 4 Rows

Lions Tongue - Screen-backCode Grit Size

LA1231 120 Grit 280 x 230mm

LA1279 180 Grit 280 x 230mm

Casting & Forming

28

SG500 One Hand Cast SawProduct code: NV3418

Lightweight oscillating, one hand cast saw allowing for easy one-handed use.

Includes: 1 x Allen key, 1 x 50mm Sawblade and 1 x 65mm Sawblade.

● Speed: 12,000 - 21,000 oscillations/min ● Noise level : 85 dB ● Weight: 1.1kg ● Charging Voltage: 240V

Oscimed Cast Saw Product code: LA4631

Very popular economically priced, ergonomic, modern and compact cast cutter/saw. Innovative balancing system by belt, allowing easy one-handed use without effort and without getting tired.

Supplied with 2 blades: 50mm and 65mm.

● Speed: 12,000 to 21,000 oscillations/min ● Noise level : 65-78 dB ● Weight: 1.07kg ● Voltage: 240V

Oscimed Replacement BladesCode: Description

LA4634 Blade - 50mm

LA4635 Blade - 65mm

cast saws

Oscimed VacuumProduct code: LA4639

Dust vacuum for use with the Oscimed Cast Saw. Possesses 4 levels of filtration and filters dust down to 3 microns. Includes a support for the saw, as a well as a vacuum hose.

● Capacity: 20 litres ● Weight : 12 kg ● Voltage: 240V

SG500 One Hand Cast SawBattery Powered Product code: NV3413

Lightweight oscillating, one hand cast saw with battery and charging unit.

Includes: 1 x Battery, 1 x Charging unit, 1 x Allen key, 1 x 50mm Sawblade and 1 x 65mm Sawblade.

● Speed: 15,500 - 21,000 oscillations/min ● Noise level : 85 dB ● Weight: 1.1kg ● Charging Voltage: 240V

Casting & Forming

29

SG600 Cast Saw Product code: NV3410

Oscillating cast saw. Ideal for cutting plaster and synthetic bandages.

Includes: 1 x set of wrenches, 1 x 50mm sawblade and 1 x 65mm sawblade.

● Speed: 12,000 to 21,000 oscillations/min ● Noise level : 70 dB ● Weight: 1.8kg ● Voltage: 240V

SG600 CompleteProduct code: NV3411

Includes SG600 Cast Saw & Dust Extraction

This full cast cutting solution includes:

● SG600 Cast Saw (as above) ● 240v Dust Extraction Unit ● Unit Handle ● Cast Saw Holder

Replacement blades Code Circumference

NV3430 50mm

NV3431 65mmStandardØ 50mm

Heavy DutyØ 65mm

cast saws

SG800 Cordless Cast SawProduct code: NV3416

Oscillating, battery powered cast saw.

Includes: 1 x battery, 1 x charging unit, 1 x set of wrenches, 1 x 50mm sawblade and 1 x 65mm sawblade.

● Speed: 14,500 oscillations/min ● Noise level : 70 dB ● Weight: 1.3kg ● Charging Voltage: 240V

Spares for Scheiber SawsCode Description

NV3420 Charging Unit

NV3419 Replacement Battery

Casting & Forming

30

Prosthetic Cast SocksProsthetic cast socks provide a smooth surface for plaster casting while protecting the residual limb. Fine gauge tubular knit cast sock which allows for great stretch in both length and width.

Code Type Type Toe Length Per Pack

CP2846 Below Knee Round 51cm 12




CP2854 Below Knee Pointed 51cm 12




CP2862 Above Knee Round 51cm 12

CP2864 Above Knee Round 61cm 12

CP2866 Above Knee Pointed 51cm 12

CP2868 Above Knee Pointed 61cm 12

Cast PantsCast Pants allow the modesty of a patient to be protected helping to eliminate embarrassing moments. The special design and use of fine gauge cotton allows for great stretch. Both legs are seam free.

casting interFaces

Code Body Length Leg Length Body Width

CP2872 40cm 40cm 25cm - 56cm

Foot Cast Socks Foot Cast Socks make taking casts of the foot quick and clean. Designed specifically for taking casts of the foot, The Cast Socks feature a special reciprocated heel and toe that helps the sock conform to the foot.

Code Shoe Size Socks Per Pack

CP2874 8 12

CP2876 9 12

CP2878 10 12

CP2880 11 12

CP2882 12 12

CP2884 13 12

CoolMax Cranial SockThe CoolMax cranial sock was designed as a casting interface for infant cranial remoulding orthoses. It intimately conforms to the shape of the child, so that it reflects well when working with lasers.

Code Description

CP2886 Cranial Sock

CP2888 Cranial Sock with Ties

casting & forming

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