Research Final Presentation

Investigation of the Effectiveness of Plaster Based

Casting and Polystyrene Casting for
Transtibial Prosthesis.

Presented by : Ananika Sirichanthaphan 5718023

Daliya Uma 5718026
Harashdeep Grover 5718037
 CONTENTS

Introduction and objective

Methodology
Result
Discussion
Conclusion
Reference
 Introduction and objective

2005 2008
Plaster based 2003
PF-modified
casting CIR Sand Casting CIR PS Casting
CIR PS Casting
 Introduction and objective
Title : CIR casting system for making Transtibial sockets
(by Yeongchi Wu, et al, Prosthetics and Orthotics International March 2009)

2005 CIR PS Casting

Advantages
1. Plaster-less casting
2. Minimal waste
3. Affordable
4.Environmentally-friendly

A single case study comparing three casting techniques.

 Introduction and objective
Title : CIR casting system for making Transtibial sockets
(by Yeongchi Wu, et al, Prosthetics and Orthotics International March 2009)

Data from a case study

Conclusion: PS casting provides precise positive model over the Sand Casting
Our criticism: PS casting tend to make smaller casting.
 Introduction and objective
Title : Preliminary experiences with the CIR casting system for transtibial prosthetic sockets.
(by N. H. THANH, et al, Prosthetics and Orthotics International June 2009)

Sand-Casting PS- Casting

(n=28) (n= 10)
Stump Socks 2-5 (layers) 1 (layer)
Good fit 68% 80%
Loose fit 17.9% 0%
Tight fit 14.2% 20%

Conclusion: PS-casting provides better casting than sand casting with one stump sock for the total
contact socket.

Our criticism: PS casting tend to make smaller casting.

 Introduction and objective
Title : Development of Immediate fitting socket system for artificial leg
( K. Sasaki, et al, IEEE, EMBS, 2003)

Important parameters for the

casting during walking

1. Beads size: 0.5mm

2. Negative pressure: -100kPa Our critism
3. Rigid granule (ceramic) PS casting can be controlled by
1.Hardness (Density) of beads
2.Size of Beads Effects the
3.Compression force (negative pressure) PS casting
4.Flexibility of the Bag system
 Introduction and objective
Title : Development of Immediate fitting socket system for artificial leg
( K. Sasaki, et al, IEEE, EMBS, 2003)

Negative pressure High rigidity Rumpf’s equation

1- ε H
σ 
APB: Airtight Particle Bag ε D 2

σ: Rigidity ε: Porosity
D: Particle diameter H: Compression force
 Introduction and objective
Problem statement : The relationship between these variables have not
been investigated as yet.

Objective

To optimize the PS casting by

determining the accuracy, durability and
surface roughness of the PS casting
Vs
method by comparing with the
traditional casting method.
 Introduction and objective
During suction, Polystyrene beads shrink. The amount of shrinkage
depends on factors including:
N. H. THANH ,ISPO Vancouver in 2007

S M
D V
Size of beads Material of bag

Density of beads Vacuum pressure

 Introduction and objective
What are the optimized Provides high rigidity
parameters? of the cast
High
density
beads
Provides
smooth
surface

High Trans- Small

size of
negative
pressure tibial beads

Prevents
shrinkage of
beads
Elastic
bag
Follows stump contour
without wrinkle
 Methodology
Plaster Based Casting

Plastic cylindrical PS Casting

model
 Methodology

S D M V

Bag material Vacuum

Size of beads Density of beads
pressure

• Small beads • 0.028 g/ cm3 (Low) • Elastic bag • High pressure (>80kpa)
(0.5-1.2 mm.) (TPU bag)
• 0.174 g/ cm3 (High) • Medium pressure
• Non elastic bag (46-55kpa)
(HDPE) • Low pressure
(19-27kpa)
 Methodology
Polystyrene casting Small beads
(0.5-1.2 mm.)

High density Low density

0.174 g/ cm3 0.028 g/ cm3

Elastic Non elastic Elastic Non elastic

bag bag bag bag

High pressure
(-80kpa)

Medium pressure
(-50kpa)

Low pressure
(-20kpa)
 Methodology
Polystyrene casting

Set the POM Apply plastic bag Apply stocking Roll the casting bag Apply vacuum
pressure
 Methodology

Accuracy

Experimentation
Of PS casting in
13 conditions
(including POP)

Durability Surface
roughness
 Methodology
Test1: Accuracy of positive cast measurements
1. Circumferences in millimeters
2. Height in millimeters

The height =
marking two
reference points
50mm

Plastic cylindrical model Positive model

 Methodology
Test 2: Durability test

Force acting on the cast Cast deformation

 Methodology
Test 3: Surface roughness test 1 𝐿
Ra = ‫׬‬0
|𝑓(𝑥)|𝑑𝑥
Evaluated by following ISO 4288 and ISO 3274 , Surface texture. 𝐿
1 𝐿 2 𝑑𝑥
Rq = ‫׬‬ 𝑓(𝑥)
40 mm 𝐿 0

Dial gauge
accuracy Ra: Arithmetical roughness
0.05mm

Dial gauge Rq: Root Mean Square roughness

L: Scanning evaluation length
x: Sampling distance
0.15
Roughness height (mm)

0.12

0.09
Amplitude (Rq)
0.06
Average roughness (Ra)
0.03

0
0 5 10 15 20 25 30 35 40
Evaluation length (mm)
 Result
Test1: Accuracy of positive cast measurements
Non-Elastic Most
327
Elastic bag bag accurate level
52

control
Circumference (mm)

51
325
control Elastic bag Non-Elastic bag

Height (mm)
50
323

321 49

319 48

317 47

315 46

Conditions of casting Conditions of casting

PS casting
Stable Dummy 170mg /80kpa 170mg /50kpa 170mg /20kpa
Plaster Base Casting 28mg /80kpa 28mg /50kpa 28mg /20kpa
 Result
Test 2: Durability test
PS casting
Stable Dummy 170mg /80kpa 170mg /50kpa 170mg /20kpa
Plaster Base Casting 28mg /80kpa 28mg /50kpa 28mg /20kpa
8
7 Plaster based
Elastic bag
6 Non-Elastic bag
Displacement (mm)

5
4
3
2
1
0 Force (N)
0

4.9

9.8

14.7

19.6

24.5

29.4

34.3

39.2

44.1

49

53.9

58.8

63.7

68.6

73.5

78.4
 Result
Test 3: Surface roughness test

10 mm.
10 mm. 10 mm.
10 mm.
10 mm. 10 mm.

Plaster based casting 28mg∙ 𝐜𝐦−𝟑 /Elas/20kpa 170mg∙ 𝐜𝐦−𝟑 /Non/80kpa

 Result
Test 3: Surface roughness test Non-Elastic bag
3
Reduce roughness
2.5
(PS Rq / POP Rq)
Roughness index

1.5 Control
POP Elastic bag
1

0.5

Conditions of casting
PS casting
Stable Dummy 170mg /80kpa 170mg /50kpa 170mg /20kpa
Plaster Base Casting 28mg /80kpa 28mg /50kpa 28mg /20kpa
 Discussion
Satisfaction rating score
Best durability
6 : Excellent
5 : Good Best surface roughness 170mg/Ela./80kpa
6
4 : Normal 28mg/Ela./20kpa 170mg/Ela./50kpa
5
3 : Fair
4
2 : Bad
plaster base casting 3 170mg/Non-Ela./80kpa
1 : Very bad
2
Best accuracy 1
170mg/Ela./20kpa 0 170mg/Non-Ela./50kpa

Accuracy
170mg/Non-Ela./20kpa 28mg/Ela./50kpa
Durability
28mg/Non-Ela./80kpa 28mg/Non-Ela./50kpa
Fine Surface
28mg/Ela./80kpa
 Conclusion
Recommended Original PS casting
condition condition by Dr. Wu

100%
100
Elastic bag Non-Elastic bag
Ranking Score (%)

80

Plaster base
60
casting

40

20

0
170mg 170mg 170mg 28mg 28mg 28mg 170mg 170mg 170mg 28mg 28mg
/80kpa /50kpa /20kpa /80kpa /50kpa /20kpa /80kpa /50kpa /20kpa /80kpa /50kpa

Condition of casting
 References
Kazuhiko Sasaki, Kouhei Nakamura and Kinya Fujita, Development of Automatic Immediate Fitting Socket
system for artificial leg socket modeling using Fuzzy control, IEEE EMBS 2004,Tokyo University of
Agricuture and Technology, Japan
Miki Fairle, Yeongchi Wu, Sustainable O&P Fabrication for Developing Countries (2011) Article,
N. H. THANH, P. A. POETSMA, & J. STEEN JENSEN, Preliminary experiences with the CIR casting system for
transtibial prosthetic sockets, 33(2);130-134,June 2009, International Society for Prosthetics and
Orthotics, Copenhagen, Denmark
Therdchai Jivacate, ML Buddhibongsa Devakula, Boonyou Tipaya and Tippaporn Yesuwarn, Twenty-one months’
experience with the PF-modified CIR casting system for trans-tibial prostheses, 35(1) 70–75, 2011,
prosthetics and Orthotics International
YEONGCHI WU1,2, HECTOR R. CASANOVA1, KIM D. REISINGER1, WILLIAM K. SMITH1, & DUDLEY S.
CHILDRESS2, CIR casting system for making transtibial sockets, 33(1): 1–9, March 2009, Center for
International Rehabilitation, Chicago, and 2Northwestern University Feinberg School of Medicine,
Chicago, USA
Y. WU, H. CASANOVA, W. K. SMITH, M. EDWARDS and D. S. CHILDRESS, CIR sand casting system for trans-
tibial socket, 27,146-152,2003, prosthetics and orthotics international