A foot orthosis has been produced from self-reinforced polypropylene, using a low-cost single-sided tool machined to the shape of the individual patient’s foot.

Orthoses have been moulded in 1, 2 and 3mm thick self-reinforced polypropylene and were individually trimmed to the required shape.

In this application, self-reinforced polypropylene offers higher strength and stiffness than conventional polypropylene orthoses, whilst still allowing the part to be locally heated and shaped to the patient’s foot in the clinical environment.

Parts are less bulky and intrusive than conventional polypropylene, giving lower visibility of the orthosis and greater comfort for the user.

Compared to carbon fibre components, self-reinforced polypropylene is fail-safe, with no possibility of splintering whilst in contact with the patient.

A successful small-scale patient trial has been undertaken on the 2mm thick component, successfully giving relief to discomfort prior to surgical procedure.

- Undertaken in collaboration with Langer Biomechanics