Thermoplastics and accessories
114
Thermoplastics and accessories
Thermoplastics and accessories
Thermoplastic sheets have played an important role in the entire development of
orthopedic technology. By changing the material properties and adapting them to
the requirements and working possibilities found in technical orthopedics, the number of application fields for thermoplastic sheet materials increases. The group
of polyethylenes (PE) and polypropylenes (PP) are particularly well suited to the
construction of prostheses and orthoses. These materials are particularly light,
recognized as physiologically safe and have durable, functional applications in
orthopedic technology.
The market can also expect to see increased use of transparent copolyesters
(PETG) – particularly in the manufacture of self-supporting test sockets. The reason for this lies in its excellent vacuum-forming properties.
Otto Bock HealthCare GmbH | Materials | www.ottobock.com
Thermoplastics
For further information on thermoplastics, see the technical information for this
catalog from page 2 onwards.
115
Thermoplastics and accessories
Technical
information
ThermoLyn® Polypropylene Copolymer (PP-C)
Pedilen®
foams
Plaster/forming
techniques
The new 616T120 ThermoLyn® Polypropylene Copolymer is a sheet
material that can be thermoformed and in which by copolymerization the
good properties of polypropylene have been combined with the toughness
of polyethylene. The polypropylene copolymer (PP-C) obtained in this way
shows a considerably increased impact strength in comparison with a
polypropylene homopolymer (PP-H), especially at low temperatures. The
PP copolymer can be excellently thermoformed as well as heat-sealed and
is ideal for drawing and laying it around orthotic joints.
Advantages at a glance
Lamination
technique
Silicones
•
•
•
•
•
Low weight
Good rigidity
High impact strength
Little tendency to white fracture
Little shrinkage
Fields of Application
PU Resin Kit
Polytol®
ThermoLyn® Polypropylene Copolymer 616T120 allows for multiple
applications such as:
• AFO’s (Ankle Foot Orthoses)
• KAFO’s (Knee Ankle Foot Orthoses)
• FFO’s (Functional Foot Orthoses)
Thermoplastics
Water transfer
printing
The processing temperature is 185 ºC / 365 °F for convection and
infrared ovens or 215 ºC / 419 °F for heating plates. Thermopaper can
be used to give the ThermoLyn® Polypropylene Copolymer an appealing
design. You can find a selection of designs for children, teenagers and
adults on page 118 of this catalog. The new ThermoLyn® PP Copolymer
is particularly appropriate if you require increased impact strength as well
as good thermoforming properties.
646S1=14.06GB
Order no. (ordering example):
Article number
616T120
=
=
Thickness
2
Article number
616T120
Thickness
2 mm, 3 mm, 4 mm, 5 mm, 6 mm
Sheet size
(length × width)
2,000 × 1,000 mm
Color
Natural colors
ThermoLyn® is a registered trademark of Otto Bock.
116
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Thermoplastics and accessories
ThermoLyn® Polypropylene Homopolymer (PP-H)
Processing temperature 215 ºC / 419 °F (heating plate), 185 ºC / 365 °F
(convection oven), 185 ºC / 365 °F (infrared oven)
Order no. (ordering example):
Article number
616T20
=
=
Article number
Width
400
x
x
Length
400
x Thickness
x
10
616T20
Width
400 mm
Length
400 mm
Thickness
10 mm, 12 mm, 15 mm
Color
Natural colors
Order no. (ordering example):
Article number =
616T20
=
Length
2000
x Thickness
x
2
616T20
Width
1,000 mm
Length
2,000 mm
Thickness
2 mm, 3 mm, 4 mm, 5 mm, 6 mm,
8 mm, 10 mm, 12 mm, 15 mm
Color
Natural colors
Thermoplastics
Article number
ThermoLyn® is a registered trademark of Otto Bock.
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117
Thermoplastics and accessories
Technical
information
ThermoLyn® Trolene (PE-LD)
Lamination
technique
Silicones
Pedilen®
foams
Plaster/forming
techniques
Flexible polyethylene, opaque, processing temperature 125 ºC / 257 °F
for heating plates, convection ovens and infrared ovens
Order number
616T3=1
616T3=2
616T3=
616T3=
616T3=
2000x1000x2 2000x1000x3 40x32x2
Length
1,000 mm
1,000 mm
2,000 mm
2,000 mm
40 mm
Width
500 mm
500 mm
1,000 mm
1,000 mm
32 mm
Thickness
1 mm
2 mm
2 mm
3 mm
2 mm
Color
Natural
colors
Natural
colors
Natural
colors
Natural
colors
Natural
colors
PU Resin Kit
Polytol®
ThermoLyn® Polyethylene 200 (PE-HD 200)
Water transfer
printing
Hard polyethylene with low shrinkage, processing temperature
180 ºC / 356 °F (heating plate), 165 ºC / 329 °F (convection oven),
165 ºC / 329 °F (infrared oven)
Order no. (ordering example) for 616T95, 616T58, 616T60, 616T61:
Thermoplastics
Article number
616T95
=
=
Thickness
2
Order no. (ordering example) for 616T19:
Article number
616T19
=
=
Thickness
2
Color
0
Article number
616T95
Width
1,000 mm
Length
2,000 mm
Thickness
2 mm, 3 mm, 4 mm, 5 mm, 6 mm,
8 mm, 10 mm, 12 mm
Color
Natural colors
Article number
616T19
Width
1,000 mm
Length
2,000 mm
Thickness
2 mm, 3 mm, 4 mm, 5 mm, 6 mm
Color
Skin colors (0)
Article number
616T58
616T60
616T61
Width
1,000 mm
1,000 mm
1,000 mm
Length
2,000 mm
2,000 mm
2,000 mm
Thickness
3 mm, 4 mm,
5 mm, 6 mm
3 mm, 4 mm,
5 mm, 6 mm
3 mm, 4 mm,
5 mm, 6 mm
Color
Blue
Red
Yellow
ThermoLyn® is a registered trademark of Otto Bock.
118
-
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Thermoplastics and accessories
ThermoLyn® RCH 500 (PE-HD 500)
Homogenous thermoplastic with high rigidity, processing temperature
195 ºC / 383 °F (heating plate), 185 ºC / 365 °F (convection oven),
185 ºC / 365 °F (infrared oven), special dimensions / other thicknesses
can be delivered upon request
Order no. (ordering example):
Article number
616T22
=
=
Article number
x Thickness
x
1
Color
N
616T22
Width
910 mm
910 mm
Length
950 mm
1,910 mm
Thickness
1 mm, 2 mm, 3 mm,
4 mm, 5 mm, 6 mm,
8 mm, 10 mm
1 mm , 2 mm, 3 mm,
4 mm, 5 mm, 6 mm,
7 mm, 8 mm, 10 mm
Color
Natural colors (N)
Natural colors (N)
Article number
616T22
Width
910 mm
910 mm
Length
950 mm
1,910 mm
Thickness
2 mm, 3 mm, 4 mm,
5 mm, 6 mm, 8 mm
1 mm , 2 mm, 3 mm,
4 mm, 5 mm, 7 mm
Color
Skin colors (H)
Skin colors (H)
Article number
616T22
Width
910 mm
Length
1,910 mm
Thickness
3 mm, 4 mm, 5 mm
Color
Graffity (G)
Thermoplastics
1:2
Length
950
ThermoLyn® RCH 500 (PE-HD 500)
Homogenous thermoplastic with high rigidity, processing temperature
195ºC / 383 °F (heating plate), 185ºC / 365 °F (convection oven),
185ºC / 365 °F (infrared oven)
Order no. (ordering example):
Article number
616T43
=
=
Length
950
x Thickness
x
2
Article number
616T43
Width
910 mm
910 mm
Length
950 mm
1,910 mm
Thickness
2 mm, 3 mm, 4 mm,
5 mm, 6 mm
2 mm, 3 mm, 4 mm,
5 mm, 8 mm
Color
Red
Red
Article number
616T44
Width
910 mm
910 mm
Length
950 mm
1,910 mm
Thickness
2 mm, 3 mm, 4 mm,
5 mm, 6 mm
2 mm, 3 mm, 4 mm,
5 mm, 6 mm, 8 mm,
10 mm
Color
Blue
Blue
ThermoLyn® is a registered trademark of Otto Bock.
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119
Thermoplastics and accessories
Technical
information
ThermoLyn® RCH 1000 (PE-HD 1000)
Plaster/forming
techniques
High-strength material with high abrasion resistance, can also be
reshaped cold, working temperature of 215 ºC / 419 °F (heating plate),
195 ºC / 383 °F (convection oven), 195 ºC / 383 °F (infrared oven)
Order no. (ordering example):
Lamination
technique
Silicones
Pedilen®
foams
Article number
616T16
=
=
Length
950
x Thickness
x
2
Article number
616T16
Width
910 mm
910 mm
Length
950 mm
1,910 mm
Thickness
2 mm, 3 mm, 4 mm,
5 mm, 6 mm
2 mm, 3 mm,
5 mm, 6 mm
Color
Skin colors
Skin colors
Thermoplastics
Water transfer
printing
PU Resin Kit
Polytol®
Other thicknesses are available upon request.
ThermoLyn® is a registered trademark of Otto Bock.
120
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Thermoplastics and accessories
Thermoprepregs PE / PP
For reinforcing orthoses
Glass fiber reinforced thermoplastic profile
For partial reinforcement for the fabrication of ankle-foot orthoses, knee
orthoses, leg orthoses (also as test orthoses), spinal orthoses and wrist
orthoses.
The Thermoprepregs consist of thermoplastic (PE or PP) with unidirectional endless glass fiber threads (see illustration). The glass fiber rovings
are blended into the cover layers of the section and unevenly distributed
along either side. The heat-weldable side contains a higher proportion of
fibers than the opposite side to counteract distortion of the plastic sheet
material. This side can be easily recognized by its 2-mm edge radius and
“Otto Bock” logo.
In combination with the appropriate thermoplastic sheets, these Thermoprepregs can be incorporated into a custom orthosis in a single fabrication process. They provide partial reinforcement of the orthosis for optimal
fitting. Furthermore, the non-reinforced areas can be shaped as needed,
while also avoiding any distortion of parts.
646A230=GB
647H468
Thermoplastic
heat reservoir
Glass roving
Thermoplastics
top (weldable side)
Lower side
Sectional view of thermoplastic prepreg
Article number
617R11=PE
To be used for
PE=Polyethylene
PP-C=PP Copolymer
617R11=PP*
PP=Polypropylene
Width × Height × Length
20 × 3 × 1,200 mm
20 × 3 × 1,200 mm
20 × 3 × 1,200 mm
* Can be used together with ThermoLyn® Polypropylene Copolymer 616T120.
ThermoLyn® is a registered trademark of Otto Bock.
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121
Thermoplastics and accessories
PU Resin Kit
Polytol®
Lamination
technique
Silicones
Pedilen®
foams
Plaster/forming
techniques
Technical
information
ThermoLyn® PETG clear (Copolyester)
Water transfer
printing
The new copolyester from Otto Bock
Thermoplastics
ThermoLyn® PETG clear is a fracture-proof
and supertransparent copolyester. Its extremely high impact strength and excellent
vacuum-forming characteristics make this
material an ideal partner for many applications in orthopedic technology.
Function and Effects
616T183 ThermoLyn® PETG clear is used
as first layer in definitive sockets, for example
within the scope of a Harmony® fitting.
The Harmony® System is an active volume
management system for transtibial prostheses. It effectively reduces the air between
socket and liner, a process in which a pump
and a one-way valve create a vacuum. With
every step the system is activated and maintains the required vacuum within a defined
range. For this purpose, an airtight connec-
tion between the socket and the residual limb
of the prosthesis wearer, or the liner, is required.
ThermoLyn® PETG clear contributes to this
sealing which, in turn, results in increased adhesion of the socket.
Since the material is flush with the upper socket brim, the friction between the residual limb
of the prosthesis wearer and the socket is
reduced, thus putting less stress on the liner.
Advantages at a glance
• Very high impact strength
• Excellent vacuum-forming characteristics
• Especially in prosthetics:
Greater safety due to outstanding socket
adhesion
ThermoLyn® is a registered trademark of Otto Bock.
122
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Thermoplastics and accessories
Infrared oven
Preheat the infrared oven (e.g. 701E20) to 160 °C (320 °F):
a) for residual limbs up to 21 cm:
Clamp the 3-mm PETG into the 755X84= 260x8 frame, small
(diameter 260)
in combination with 755T4=360 and heat up for 2:45 min.
b) for residual limbs from 21 cm long:
Clamp the 5-mm PETG into the 755T4 =360 vacuum forming insert
(diameter 360) and heat up for 4:10 min
Convection oven
Preheat the convection oven (e.g. 701E7) to 170 °C (338 °F):
a) for residual limbs up to 21 cm:
Clamp the 3-mm PETG into the 755X84= 260x8 frame, small
(diameter 260)
in combination with 755T4=360 and heat up for 12 min.
b) for residual limbs from 21 cm long:
Clamp the 5-mm PETG into the 755T4 =360 vacuum forming insert
(diameter 360) and heat up for 13 min.
Select as small vacuum sealing disk as possible.
We recommend that you use the following equipment:
755X104=180 Vacuum pipe with sealing disk (diameter 180)
or
755X104=260 Vacuum pipe with sealing disk (diameter 260)
Thermoplastics
Remove the PETG sheet from the oven very quickly and vacuum form it
immediately with high vacuum. If required, shape undercuts with hot air
gun (e.g. 756E9).
Equipment:
755E9 Vacuum pump
641H13 Heat-resistant protective gloves
Order number
616T183=3
616T183=5
Sheet size
(length × width)
400 × 400 mm
400 × 400 mm
Color
Colorless
Colorless
Thickness
3 mm
5 mm
646S1=13.06GB
646T4=1.0GB
Otto Bock HealthCare GmbH | Materials | www.ottobock.com
123
Thermoplastics and accessories
Technical
information
ThermoLyn® clear (Copolyester)
Colorless
Pedilen®
foams
Plaster/forming
techniques
The processing temperature for heating plates, convection and infrared
ovens is 165 ºC / 329 °F.
Thanks to the transparency of test sockets made of ThermoLyn® clear ,
the patient’s fit and discoloration of the skin surface on the residual limb
can be monitored more closely. By heating the socket, this thermoplastic
can be reshaped at pressure points, for example.
Silicones
646A230=GB
Lamination
technique
Order no. (ordering example):
Water transfer
printing
PU Resin Kit
Polytol®
Article number
616T83
=
=
Sheet size
x
1250 x 1025 x
Thickness
3
Article number
616T83
Sheet size (length × width)
1,250 × 1,025 mm
1,250 × 1,025 mm
1,250 × 1,025 mm
Thickness
3 mm
4 mm
6 mm
For producing
Scar compression masks
Trial orthoses
Order no. (ordering example):
Thermoplastics
Article number
616T83
=
=
Thickness
8
Article number
616T83
Sheet size (length × width)
400 × 400 mm
400 × 400 mm
400 × 400 mm
400 × 400 mm
400 × 400 mm
Thickness
8 mm
10 mm
12 mm
15 mm
20 mm
For producing
Trial
orthoses
Self-supporting test sockets
(for temporary use)
See the technical information on page 24 for recommendations on
cutting work.
ThermoLyn® rigid (Polystyrene)
Colorless, for the production of self-supporting test sockets (for temporary use), processing temperature 170 °C / 338 °F in convection or
infrared oven
Order no. (ordering example):
Article number
616T52
=
=
Thickness
8
Article number
616T52
Sheet size
(length × width)
400 × 400 mm
Thickness
8 mm, 10 mm, 12 mm, 15 mm
ThermoLyn® is a registered trademark of Otto Bock.
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Thermoplastics and accessories
ThermoLyn® Europlex (Polyamide)
Colorless, for producing insoles, thermoformable at 135 °C / 275 °F in
convection and infrared oven
Order no. (ordering example):
Article number
616T70
=
=
Thickness
2
Article number
616T70
Sheet size
(length × width)
2,050 × 1,200 mm
Thickness
2 mm, 3 mm, 4 mm
ThermoLyn® ﬂexible (Ionomer)
Colorless, for producing flexible inner sockets for lower limb prostheses,
processing temperature 165 ºC / 329 °F in convection and infrared ovens
Order no. (ordering example):
=
=
Thickness
6.3
Article number
5Z3
616T39
Sheet size
(length × width)
400 × 400 mm
1,200 × 800 mm
Thickness
4.7 mm, 6.3 mm,
8.5 mm, 11.5 mm
4.7 mm, 6.3 mm,
8.5 mm, 11.5 mm
Thermoplastics
Article number
616T39
ThermoLyn® is a registered trademark of Otto Bock.
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125
Thermoplastics and accessories
Technical
information
ThermoLyn® soft (EVA)
Plaster/forming
techniques
For production of flexible inner sockets for upper limb prostheses, high
shrinkage if cooled down too quickly, translucent (color depends on skin
color), processing temperature 160 °C / 320 °F in convection and infrared
ovens
646A230=GB
Pedilen®
foams
Order no. (ordering example):
Lamination
technique
Silicones
Article number
616T69
=
=
Thickness
6
Article number
616T69
Sheet size
(length × width)
400 × 400 mm
Thickness
6 mm, 8 mm, 10 mm, 12 mm
Color
Skin colors
Article number
616T53
Sheet size
(length × width)
400 × 400 mm
Thickness
8 mm, 10 mm, 12 mm, 15 mm
Color
Colorless
Thermoplastics
Water transfer
printing
PU Resin Kit
Polytol®
For production of flexible inner sockets for lower limb prostheses, high
shrinkage if cooled down too quickly, colorless, processing temperature
160 ºC / 320 °F in convection and infrared ovens
ThermoLyn® supra soft (EVA)
For production of highly flexible transfemoral soft-walled inner sockets, processing temperature 155 °C / 311 °F in convection oven and infrared oven
Order number
616T59=10
Sheet size
(length × width)
400 × 400 mm 400 × 400 mm 400 × 400 mm
616T59=15
Thickness
10 mm
12 mm
15 mm
Color
Colorless
Colorless
Colorless
ThermoLyn® is a registered trademark of Otto Bock.
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616T59=12
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Thermoplastics and accessories
Plaster Parting Agent
For separating plaster and acrylic
Order number
85F1
Net contents
1l
Residual Limb Sock
Nylon
Order number
99B25
Length
Approx. 50 cm
Order by
Package of 10
Transpad
Order number
83T4
Dimensions
1×1 m
Thickness
1.5 mm
Thermoplastics
Flexible, transparent material for the manufacture of brackets for orthosis
and mask fixing systems.
Silicone Grease 400, Medium
For the shift sleeve of the drive unit, as well as for all cable plug connections and other places that need to be protected to prevent penetration of
sweat. Can be applied for cast isolation.
Article number
633F11
Net contents
0,100 kg
Packaging
tube
Silicone Parting Agent
CFC-free, compact and solvent-free, for separation, gliding and lubricating, protects rubber, plastic and elastomers from becoming brittle
Article number
519L5
Net contents
0,400 l
Extremely ﬂammable
Otto Bock HealthCare GmbH | Materials | www.ottobock.com
127
Thermoplastics and accessories
Technical
information
Trial Sheeting
Colorless, for the manufacture of transparent trial shoes for diabetic feet
Plaster/forming
techniques
Order no. (ordering example):
Lamination
technique
Silicones
Pedilen®
foams
Article number
616T6
=
=
Sheet size
400 x 450
x Thickness
x
1.5
Article number
616T7
616T6*
Material properties
Hard
Flexible
Description
Thermoplastically moldable at
175 °C / 347 °F
Soft and flexible, high rigidity,
thermoplastically moldable at
100 °C / 212 °F
Sheet size (length × width)
600 × 450 mm
400 × 450 mm, 600 × 450 mm
Thickness
1.2 mm, 2.0 mm
1.5 mm
Thermoplastics
Water transfer
printing
PU Resin Kit
Polytol®
* We recommend the ”Vacupress“ vacuum-forming device, which you can find in the ”Planning and Equipment Catalog“
646K10=GB under vacuum and pneumatic devices.
128
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Thermoplastics and accessories
ThermoLyn® Pedilon (LTT Polyester)
Low-temperature polyester, can be stretched when heated, heat to
60 °C / 140 °F in water bath.
Thanks to ThermoLyn® Pedilon’s low forming temperature of 60 °C /
140 °F, it can be molded directly on the patient’s body. This eliminates the
need for making casts or models, a time-consuming process. This sheet
material is especially suitable for clinical use, where the patient must be
treated immediately.
Order no. (ordering example):
Article number
616T73
Article number
=
=
Perfor./fig. x
NP
x
Sheet size
90 x 60
x
x
Thickness
3.2
616T73
Perforation
None (NP)
Fine (FP)
Medium (MP)
Rough (GP)
Sheet size (L × W)
(in cm)
60 × 43
90 × 60
60 × 43
60 × 43
60 × 45
60 × 43
60 × 45
90 × 60
Thickness (in mm)
2
3.2
1.6
2
2.5
2
3.2
4
4.0
None (NP)
2
Fine (FP)
3.2
Medium (MP)
Rough (GP)
Application example:
Thermoplastics
Hand Orthosis
Material: 616T73=450x600x2 ThermoLyn® Pedilon
Place ThermoLyn® Pedilon material precut part in the water pan
759P1=220 filled with around 60 ºC / 140 °F warm water. The material
becomes transparent when it reaches its molding temperature. Remove
the cutout with a wooden spatula and allow the water to drip off.
Moisten hand and lower arm well with cold water.
Place the warm ThermoLyn® Pedilon over the hand and lower arm.
For the finished product, see the “Thermoplastics” table on page 6.
ThermoLyn® is a registered trademark of Otto Bock.
Otto Bock HealthCare GmbH | Materials | www.ottobock.com
129
Thermopapers
Technical
information
Thermopaper “Arles”
Pedilen®
foams
Plaster/forming
techniques
For coloring sheet materials
Order number
623P17=2
623P17=5
623P17=10
Width
80 cm
80 cm
80 cm
Length
2m
5m
10 m
1:5
Silicones
Thermopaper “Jeans”
PU Resin Kit
Polytol®
Lamination
technique
For coloring sheet materials
Order number
623P21=2
623P21=5
623P21=10
Width
80 cm
80 cm
80 cm
Length
2m
5m
10 m
Water transfer
printing
1:5
Thermopaper “Tiger”
Thermoplastics
For coloring sheet materials
Order number
623P30=2
623P30=5
623P30=10
Width
80 cm
80 cm
80 cm
Length
2m
5m
10 m
1:5
processed
Thermopaper “Escargot”
For coloring sheet materials
Order number
623P31=2
623P31=5
623P31=10
Width
80 cm
80 cm
80 cm
Length
2m
5m
10 m
1:5
processed
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Thermopapers
Thermopaper “Penguin”
For coloring sheet materials
Order number
623P32=2
623P32=5
623P32=10
Width
80 cm
80 cm
80 cm
Length
2m
5m
10 m
1:5
processed
Thermopaper “Pinky stripes”
For coloring sheet materials
Order number
623P33=2
623P33=5
623P33=10
Width
80 cm
80 cm
80 cm
Length
2m
5m
10 m
1:5
Thermoplastics
processed
Thermopaper “Bamboo green”
For coloring sheet materials
Order number
623P34=2
623P34=5
623P34=10
Width
80 cm
80 cm
80 cm
Length
2m
5m
10 m
1:5
processed
Thermopaper “Bamboo black”
For coloring sheet materials
Abb: Bamboo black
Order number
623P35=2
623P35=5
623P35=10
Width
80 cm
80 cm
80 cm
Length
2m
5m
10 m
1:5
processed
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131
Thermopapers
Technical
information
Thermopaper “Tartan blue”
Pedilen®
foams
Plaster/forming
techniques
For coloring sheet materials
Order number
623P36=2
623P36=5
623P36=10
Width
80 cm
80 cm
80 cm
Length
2m
5m
10 m
1:5
Silicones
processed
Lamination
technique
Thermopaper “Aqua blue”
Water transfer
printing
PU Resin Kit
Polytol®
For coloring sheet materials
Order number
623P39=2
623P39=5
623P39=10
Width
80 cm
80 cm
80 cm
Length
2m
5m
10 m
1:5
Thermoplastics
processed
Thermopaper “Aqua red”
For coloring sheet materials
Order number
623P40=2
623P40=5
623P40=10
Width
80 cm
80 cm
80 cm
Length
2m
5m
10 m
1:5
processed
Thermopaper “Safary”
For coloring sheet materials
Order number
623P43=2
623P43=5
623P43=10
Width
80 cm
80 cm
80 cm
Length
2m
5m
10 m
1:5
processed
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Otto Bock HealthCare GmbH | Materials | www.ottobock.com
Thermoplastics
Thermopapers
Otto Bock HealthCare GmbH | Materials | www.ottobock.com
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