KAFO with Carbon System Joints in Anchor Lamination Technique

Mount the system joints by using the assembly/lamination dummys and in accordance with the exploded view drawings. When laminating, the dummys serve as placeholder for the system joints’ joint cases.
Note: You can find exploded view drawings in our product catalogue System Joints and Articulated System Side Bars.

Mark the lower edge of the dummy on the system stirrup and the upper edge on the system anchor. Everything above or below this line must not be bent, as these areas are part of the system joint later.
Note: All waterproof system anchors are also available in a bent shape, which can be used in case of large gaps between system anchor and leg to avoid falling below the bending radii.

Clamp the system stirrup into a vice with plain jaws to bend it. Pay attention to the marking to avoid a subsequent deformation of the joint areas and to be able to bend very close to the joint.

Adapt the system stirrup to the shape of the model. Bend the system stirrup neck with a bending iron. Only bend in one direction.
Note: Do not use a hammer and do not heat the material.

Remove the system stirrup from the vice and check the distance from the system stirrup to the model.

Adapt the system stirrup to the shape of the model. Bend the lower part of the system stirrup with a bending iron. Only bend in one direction.
Check the distance to the model.

Clamp the system anchor into a vice with plain jaws to bend it. Pay attention to the marking to avoid a subsequent deformation of this area which is adhered to the joint later. While bending, please consider the applicable bending radii and use proper tools (bending iron with round edges).
Note: You will find more detailed information in the Instructions for Use for Orthotists or Qualified/Trained Experts for System Anchors for Waterproof System Joints.

Check the distance from system anchors and stirrups to the positive cast. Please make sure to have enough space left for the reinforcing profile and the reinforcement layers in order to avoid later strains to the laminate. Thus, the joint areas stay parallel.

Grind the system stirrup and the system anchor. Always grind in direction of rolling. Remove all notches from bending and avoid sharp edges.
Note: System ankle joints with dorsiflexion stop, which can be adjusted by filing, should always be mounted in their pre-assembled neutral position without changing the dorsiflexion stop.

Use a sharp knife to remove the thin laminate layer over the dummies. Remove the screws.

Mark the cutting edges by following the previously modified edge of the later orthosis. For optimally integrating the system joint and gaining the maximum possible bearing surface at the foot piece, only remove as much of the laminate as necessary and as little as possible.

Remove all laminate parts which are no longer necessary. Then, you can remove the orthosis parts from the model.

Clean all the joint areas as well as the system stirrup before you temper the parts of the orthosis. Heat all wax residues with a hot air blower (1) and blow
the liquefied insulating wax out of the hollows (2). Remove all residues with a cloth (3). Remove the PVA film tube as well.

Temper all parts of the orthosis before you grind them. Place the orthosis parts into a cold convection oven and heat it up slowly. When tempered, the parts of the orthosis are stable and can be worked in the best possible way.
Important! Also follow the processing instructions for epoxy resin.