The use of flexible polyurethane foam in orthotics

The casting of flexible polyurethane foam into a wide range of customised shapes has been found to offer a relatively straightforward solution to a number of problems associated with providing support for the physically handicapped. This note describes the techniques used for the production of such supports and reports on clinical experience of their use. A suitably prepared plaster cast of the patient, obtained in the usual way via vacuum consolidation of polystyrene beads, forms the lower surface of a wooden moulding box. Suitable quantities of the two chemicals, an isocyanate and a polyol, are then thoroughly and rapidly mixed together before being poured into the moulding box over which a weighted lid is placed to contain the foam and to improve its consistency. After removal, the finished product can then be trimmed and if necessary covered with fire-retardant leathercloth. To date polyurethane foam mouldings have been used with considerable success as seat cushions, seat backs and as spinal body supports which allow a patient to be nursed prone and supine following spinal fusion.